Lit 18616 01 24 PDF

LAW EE Marine Outboards T9.9T F9.9T SERVICE MANUAL y YVAMAHA MOTOR CO.,LTD. 290229 @NOTICE This manual has been prepared by the Yamaha Motor Company Ltd. primarily for use by Yamaha dealers and their trained mechanics when performing maintenance procedures and repairs to Yamaha equipment. It has been written to suit the needs of persons who have a basic understand- ing of the mechanical and electrical concepts and procedures inherent in the work, for without such knowledge attempted repairs or service to the equipment could render it unsafe or unfit for use. Because the Yamaha Motor Company Ltd. has a policy of continuously improving its products, models may differ in detail from the descriptions and illustrations given in this publication. Use only the latest edition of this manual. Authorised Yamaha dealers are notified periodically of modifica- tions and significant changes in specifications and procedures, and these are incorporated in suc- cessive editions of this manual. ‘T9.9T, FOOT ‘SERVICE MANUAL ‘© 1993 Yamaha Motor Co, LTD. ‘1st Edition, July 1994 All rights reserved. No part of this publication may be repro- duced or transmitted in any form or by any ‘means including photocopying and record- ing without the written permission of the copyright holder. Such written permission must also be obtained before any part of this publication is stored in a retrieval system of any nature. Printed in Japan P/N LIT-18616-01-24eS HOW TO USE THIS MANUAL MANUAL FORMAT All of the procedures in this manual are organized in a sequential, step-by-step format. The information has been complied to provide the mechanic with an easy to read, handy reference that contains comprehensive explanations of all disassembly, repair, assembly, and inspection operations. In this revised format, the condition of a faulty component will precede an arrow symbol and the course of action required will follow the symbol, e.g., + Bearing Pitting/Damage —- Replace. To assist your to find your way about this manual, the Section Title and Major Heading is given at the head of every page. ‘An Index to contents is provided on the first page of each Section. ‘THE ILLUSTRATIONS ‘Some illustrations in this manual may differ from the model you have. This is because a procedure described may relate to several models, though only one may be illustrated. (The name of model described will be mentioned in the description). REFERENCES These have been kept to a minimum; however, when you are referred to another section of the manual, you are told the page number to go to. SPECIFICATIONS ‘These are given in bold type at each procedure. Itis not necessary to leave the section dealing with the procedure in order to look up the specifications. Itis important to note the differences in specifications of models. Where a procedure relates to more than one model, the main differences in specificarions will be shown in a following table. stam 08" | Te9MH/F99AM |T39EH/F9SAEM! TOSER/FSSAE |FROMH/FS9BM| — FOOBEM Fooae Staring system | Manualstan | Electricstat | Electicstat’ | Manvalstat | Elecvicstat | Electic start Control system | Manual control | Manual conteri | Remote control | Manual contr! | Manual control | Remote contro! Tinsystom | Manualuit | Manwaltit | Manualtit | Manualt | Manual tit | Manual it= WARNINGS, CAUTIONS AND NOTES Attention is drawn to the various Warnings, Cautions and Notes which distinguish important Information in this manual in the following ways. QS The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED! 4 WARNING Failure to follow WARNING instructions could result in severe injury or death to the machine operator, a bystander, or a person inspecting or repairing the outboard motor. CAUTION: ACAUTION indicates special precautions that must be taken to avoid damage to the outboard motor. NOTE: ‘A NOTE provides key information to make procedures easier or clearer. IMPORTANT: This part has been subjected to change of specification during production.HOW TO READ DESCRIPTIONS 1. An easy-to-see disassembly illustration is mainly provided for a disassembly job. 2, Numbers are given in the order of a disassembly job in the disassembly illustration. 3. An explanation of jobs and notes is presented in an easy-to-read way by the use of symbol marks. ‘The meanings of the symbol marks are given on the next page. 4, Ajob instruction chart accompanies the assembly illustration, providing the order of jobs, names of parts, notes in jobs, etc. 5. In addition to the disassembly illustration, “REMOVAL POINTS” is provided to supplement in detail the explanation which does or cannot necessarily cover the main jobs. 6. Jobs necessary before and after those which are not included in the disassembly illustration are explained before the same illustration as related jobs. @ Section © Remarks @ Preparation for removal @ Removal points @ Order of removal ® Extent of removal @ Part name @® Symbol mark © Qty @ Exploded diagram (rowel GB] crunoen nexo vaLve ao caxourr& SYMBOLS Symbols @ to @ are designed as thumbtabs to indicate the content of a chapter. @ General Information @® Specifications @ Periodic Inspection and Adjustment @ Fuel System ®© Power Unit © Lower Unit @ Bracket Unit @® Electrical System @ Trouble-shooting Symbols @ to @ indicate specific data: @ Special Too! @ Specified liquid @ Specified grease 8 Specified engine speed @ Specified torque ® Specified measurement ® Specified electrical valve [Resistance (2), Voltage (V), Electric current (A) ‘Symbol @ to @ in an exploded diagram indi- ‘cate grade of lubricant and location of lubrication point: cy ® ® Apply Yamaha engine oil ® Apply Yamaha gear-case lubricant ® Apply molybdenum disulfide oil @ Apply water resistant grease (Yamaha ma- a 4 rine grease A, Yamaha marine grease) Symbols @ to @ in an exploded diagram indicate grade of sealing or locking agent, and location of application point: @ Apply Gasket maker® @ Apply LOCTITE® No. 271 (Red LOCTITE) @ Apply LOCTITE® No. 242 (Blue LOCTITE) @ Apply LOCTITE® No. 572 NOTE: —__ In this manual, the above symbols may not be used in every case.INDEX fy {my Uv GENERAL INFORMATION SPECIFICATIONS PERIODIC INSPECTION AND ADJUSTMENT FUEL SYSTEM POWER UNIT LOWER UNIT BRACKET UNIT ELECTRICAL SYSTEM TROUBLE-SHOOTING Oa m i a 5 a 7 pS! o So Z|. || = Lt | eal] 2 2 @ < 2 zo anil aa>| | f|| 2 Ml 2 | SGM s Mea S] 5/5 lasGEN | INFO | t CHAPTER 1 GENERAL INFORMATION IDENTIFICATION .... SERIAL NUMBER nnn ENGINE SERIAL NUMBER .. STARTING SERIAL NUMBERS . SAFETY WHILE WORKING FIRE PREVENTION VENTILATION .. SELF-PROTECTION .. OILS, GREASES AND SEALING FLUIDS GOOD WORKING PRACTICES uw... DISASSEMBLY AND ASSEMBLY SPECIAL TOOLS . FOR TUNE-UP ... nnn FOR POWER UNIT SERVICE 16 FOR LOWER UNIT SERVICE 18GEN INFO IDENTIFICATION & IDENTIFICATION ‘SERIAL NUMBER The serial number of the outboard motor is stamped on a plate attached to the port side of the clamp bracket. NOTE: For USA model: As an anti-theft measure, a special label on which the outboard motor serial number is stamped is bonded to the portside of the clamp bracket. The label is specially treated so that peeling it off causes cranks across the serial number. @ Model name @ Approved model No. @ Transom height @ Serial number ENGINE SERIAL NUMBER The engine serial number is stamped on the cylinder body. STARTING SERIAL NUMBERS ‘The starting serial number blocks are as follows: “Approved Model | mecoiNo. | SerialNumber | 1; 303720~ Iroomu/rooam| 6c8 | ut ynneag 1: 470253~ TasEH/FOAEM! 668 | Wt: 796920- 'S: 100839— TO9ER/FO9AE| 668 409897~ UL: 761822~ 'S: 009053 FO.9MH/F9.9BM| 6G9 tesonaay. 'S:200265~ F9.9BEM 6G9 Tes002s4— S:101145— F9.9BE 6c9 aoaG ies T SAFETY WHILE WORKING & 12 SAFETY WHILE WORKING The procedures given in this manual are ‘those recommended by Yamaha to be follow- ‘ed by Yamaha dealers and their mechanics. FIRE PREVENTION Gasoline (petrol) is highly flammable. Petroleum vapor is explosive if ignited. Do not smoke while handling gasoline (petrol), and keep it away from heat, sparks, and open flames. VENTILATION Petroleum vapor is heavier than air and it in- haled in large quantities will not support life. Engine exhaust gases are harmful to breathe. When test-running an engine indoors, maintain good ventilation. ‘SELF-PROTECTION Protect your eyes with suitable safety spec- tacles or safety goggles when using compressed air, when grinding or when doing any operation which may cause particles to fly off. Protect hands and feet by wearing safety gloves or protective shoes of appropriate to the work you are doing. OILS, GREASES AND SEALING FLUIDS Use only genuine Yamaha oils, greases and sealing fluids or those recommended by Yamaha.GEN INFO T SAFETY WHILE WORKING Cc Under normal conditions of use, there should be no hazards from the use of the lubricants mentioned in this manual, but safety is all- important, and by adopting good safety practises, any risk is minimized. ‘A summary of the most important precautions is as follows: 1. While working, maintain good standards of personal and industrial hygiene. 2. Clothing which has become contaminated with lubricants should be changed as soon as practicable, and laundered before further use. 3. Avoid skin contact with lubricants; do not, for example, place a soiled wiping- rag in one’s pocket. 4, Hands, and any other part of the body which have been in contact with lubricants or lubricant-contaminated clothing, should be thoroughly washed with hot water and soap as soon as practicable. 5. To protect the skin, the application of a suitable barrier cream to the hands before working is recommended. 6. A supply of clean lint-free cloths should be available for wiping purposes. GOOD WORKING PRACTICES 1. The right tools Use the special tools that are advised to protect parts from damage. Use the right tool in the right manner — don't improvise. 2. Tightening torque Follow the torque tightening instructions. When tightening bolts, nuts and screws, tighten the large sizes first, and tighten inner-positioned fixings before outer- positioned ones. 13Ea T SAFETY WHILE WORKING QS 3. Non-reusable items Always use new gaskets, packings, O- rings, oil seals, split-pins and cir etc. on reassembly. DISASSEMBLY AND ASSEMBLY 1. Clean parts with compressed-air on dis- assembling them. 2. Oil the contact surfaces of moving parts on assembly. 3. After assembly, check that moving parts ‘operate normally. 4. Install bearings with the manufacturer's markings on the side exposed to view, and liberally oil the bearings. 5. When installing oil seals, apply a light coating of water-resistant grease to the outside diameter. 14a T SPECIAL TOOLS QS re SPECIAL TOOLS The use of correct special tools recommended by Yamaha will aid the work and enable accu- rate assembly and tune-up. Improvisations and use of improper tools can cause damage to the equipment. . and Canada, use part number starting with “YB-", "YU-" or “YW-”. +For others, use part number starting with "90890-". yu-s087 SonoouTEse FOR TUNE-UP YU-1256 1. Dial gauge and stand P/N. YU-3097, YU-1256 90890-01252 2. Digital multi meter P/N. YU-34899-A 90890-06752 ‘YU-34899-A 90890-06752 3. CDI tester Yu-91022-B P/N, YU-91022-8 18mt SPECIAL TOOLS Yu-38228 90890-06751 LP @ Sg Yu-39277-A 90890-03141 AD 90890-06760 Yeas 0800 06756 O a Gr 200 KY ON ean soo 0521 SONS ve 16 4, Compression gauge P/N. YU33223, 90890-06751 5. Timing light P/N. YM-33277-A 90890-03141 6. Tachometer P/N. YU-8036-A 90890-06760 7. Mity Vac P/N. YB-35956 90890-06756 FOR POWER UNIT SERVICE 1. Flywheel puller P/N. YB-6117 90890-06521GEN INFO SPECIAL TOOLS 2. Flywheel holder 6.6130 90890-06522 pines ore 90890-06522 3. Piston ring installer e: : ‘YB-34454 90890-06529 P/N. YB-34454 90890-06529 90890-06069 90890-04019 YM-1122, ‘90890-06801 W 4, Shaft holder P/N. 90890-06069 5. Valve spring compressor P/N. YM-1253 90890-04019 6. Valve guide remover P/N. YM-1122 90890-06801mT SPECIAL TOOLS YB-6308 © 90890-06802 YM-1196 ‘90890-06804 YM-91043-C 90890-01311 YB-6265 7. Valve guide installer P/N. YB-6308 90890-06802 8. Valve guide reamer P/N. YM-1196 90890-06804 9. Valve seat cutter set P/N. YM-91043-C 90890-06803 10. Valve adjuster P/N. YM-8035 90890-01311 FOR LOWER UNIT SERVICE 1. Backlash indicator P/N. YB-6265 90890-06706 18Lt SPECIAL TOOLS ‘90890-06501 YB-6228 90890-06515 YB-6219 ‘90890-06534 ‘90890-06538 19 2. Stopper guide plate PIN. 90890-06501 3. Drive shaft holder P/N. YB-6228 90890-06515 4. Bearing separator P/N. YB-6219 90890-06534 5. Bearing puller P/N. 90890-06535 6. Stopper guide stand P/N. 90890-06538GEN INFO SPECIAL TOOLS eS 7. Drive rod yeeort 0800-06604 PIN, YB-6228, YB-6071 90890-06605 90890-06602 90890-06606 90880-00604 90890-06605 90890-06606 / / 8. Needle bearing attachment (T9.9/F9.9A) P/N. YB-6298 90890-06618 Y8-6298, ‘90890-06618 v © We eoa0) feese098i71 9. Needle bearing attachment (F9.9/F9.9B) Y8-6081 90890-06616 P/N. YB-6230, YB-6081 90890-08617 90890-06616 ® @ 10. Magnet base P/N. YU-34481 90890-06705 Yu-34481 ‘90890-06705 ") - 11, Oil seal installer YB-6022 P/N. YB-6022 © 1-10IRE T SPECIAL TOOLS 12. Bearing installer ‘YB-6015 '90890-06632 ‘YB-6085 90890-08625 P/N. YB-6015, YB-6085 90890-06632 90890-06625 13, Pinion nut holder P/N. YB-6078 ‘YB-6078 YB6290 E3422 15. Pinion height gauge (F9.9/F9.9B) PIN. YB-34232 Ee 16. Bearing housing puller 'yB-06234 ‘90890-06503 Brukyetoase 90890-06503GEN INFO | SPECIAL TOOLS [reso ——— 17. Slide hammer set P/N. YB-6096 90890-06603 18. Center bolt PIN. 90890-06603 2a ‘30890-06603 19. Bearing depth plate PIN 90890-06603 {90890-06707 20. Shimming plate PIN. 90890-06701 Seg[sPec = CHAPTER 2 SPECIFICATION GENERAL SPECIFICATIONS .. PROPELLER SELECTION MAINTENANCE SPECIFICATIONS 24 ENGINE ..... : = 24 ELECTRICAL eee neeinntntnnttntnntntntntenieinnnnetnticsets BQ) CDI unit resistance chart ..... 29 DIMENSION ...... 244 TIGHTENING TORQUE ... ~ 212 GENERAL TORQUE SPEC! ~ 242SPEC) U™| GENERAL SPECIFICATIONS QS GENERAL SPECIFICATIONS Tod a ae T9.9MH/F9.9AM | T9.9EH/F9.9AEM | T9.9ER/F9.9AE vera ingih mm) 689,39) 575 226) Overall wn mm) #20 189) 3281128) Overl neigh | mm | ee 1051 (41) wo mm (in) 1178 (46.4) uy} mmiiny 1254 (49.4) Boat transom height (Ss) mm (in) = 381 (15.0) (| mmciny ‘508 (200) | iimtny 535 (250) Weight (without propeller) (S) kg (Ib) = 44.5 (98) () kg (Ib) 43.5 (96) 45.0 (99) 45.5 (100) (WL) | kot) 440 (97) 455 (100) 460 (101) Maximum ouput Fw (pep 74 99/4500 Speed range a fulthote ‘om oo0~s000 Speed range ating om 1150-90 Speod range at ling bt to00 50 Mam fol oneuttion im 33 (us/imp oa) (087/07 Engine ype Totroke OC Number of etinders 2 ‘Total placement em? (eum) 232 (1416) Bore and Svoke im Sm Sao aaa xn) sexier) Compression rao ao: Spark pug Nak number Gees Number of cabursior : Carburetor staring system Prime tart Manito arrangement Cros ow Exhaust system Propeller boss {breston sytem Wet sump Ignition sytem cal Staring system Marval saat Elec dane Fuel rating PONT 6 Engine ol ype"2 SAE 1-90, 10-40 ai se, sr, 29°, Se SF-06, 6-00 Engine ol pan capecty (us/imp 10 (108/088) Gear oll type Hypoid gear oil sae sos Gear oil capacity om? (US/Imp oz) 320 (10.82/11.26) Titangl at 12"boatvansom | Dogroe 8,12, 16,20 Tap angle 2 boat vaneom| Degree 70 Shaton water angle Degree E Steering angie (et ght) Dasree artar Gear sit poston rans Gearrato 19:98(282) Reduction system spel bevel gear Propeller decton (Rear view) Glock wise Preller dive syatom Spine *2: YAMALUBE 4 is recommended *3: GEAR CASE LUBE is recommended in U.S.A. "4: Over head camshaft Forward-Neutral-Reverse 24 Pump Octane Number, (Research octane + Motor octaney2SPEC, GENERAL SPECIFICATIONS Model Led be F9.9MH/F9.9BM F9.9BEM FO.9BE ‘Overall length ‘mm (in) 863 (340) 575 (226) Overall width mm (in) 393 (155) 325 (128) Overall height ‘s) mm (in) 1004 (39.5) ©} min) 1181 (445) (UL) | mmiin) I Boat transom height (s) mm (in) 981 (15.0) ©] mmo) 508 (20.0) (ut) | mm in) a Weight (without propeller) (S) kg (Ib) 41.5 (91) 43.0 (95) 43.5 (96) wo kg (lb) 42.5 (94) 44.0 (97) 44.5 (98) (| _kg tw) = Maximum output KW (hp)/rpm_ 7.4 (9.9)/5000 Speed range at fullthrotle pm 44500-5500 ‘Speed range at idling mm 950+50 Speed range at tring rm 85050 Maximum fuel consumption un 38 (us/imp gal (1.00/084) Engine type “4 stroke OHC “4 Number of cylinders 2 Total displacement com? (cu in) 292 (14.16) Bore and Stroke mm xmm 590 x424 (in xin) (232 x1.67) Compression ratio 93:1 Spark plug NGK number CRGHS Number of carburetor 1 Carburetor starting system Prime start Manifold arrangement Cross flow Exhaust system Propeller boss Lubrication system Wet sump Ignition system col. Starting system Manual starier Electric starter Fuel rating PON 36 Engine oil type "2 SAE 0W-30, 10W-40 API SE, SF, SE-SF, SE-SF-CC, S6-CD Engine oil pan capacity £(US/Imp at) 1.0 (1.06/0.88) Gear ol type Hypoid gear oil SAE 90"3 Gear oll capacity em (US/Imp 02) 185 (625/651) Tit angle at 12" boat transom Degree 8,12, 16,20 Tip angle at 12"boat transom| Degree 70 Shallow water angle Degree Tit angle + 20 = Steoring angle (loft + right) Degree a7 +37 Gear shift position PNAS Gear ratio 13:27 (208) eduction system Spiral bevel gear Propeller direction (Rear view) Clock wise Propeller drive system Spline "4: Pump Octane Number; (Research octane + Motor octaney2 *2: YAMALUBE 4 is recommended *3: GEAR CASE LUBE is recommended in U.S.A. Over head camshaft *5: Forward-Neutral-Reverse 22PROPELLER SELECTION T9.9/F9.9A SPEC] g™| GENERAL SPECIFICATIONS Material (Propeller identification mark) *Remarks ‘Aluminnium (R) *Dual thrust Plastic (R) Available propeller (Number of blades x Diameter x pitch) 3x 11-8/4" x 9-1/4" 3 x 11-9/4" x 9-1/4" 3x 11-9/4" x 11" 3X 11-9/4" x 12-1/4" F9.9/F9.9B Material (Propeller identification mark) “Remarks ‘Aluminium (J) ‘Aluminium (J) *Dual thrust Available propeller (Number of blades x Diameter X pitch) 3 x9-1/4" x8" 3x9-1/4" xo" 3 X9-1/4" x 9-3/4" 3 X9-1/4" x 10-1/2" 3x 9-1/4" x 12" 3X 9-1/2" X6-1/2" 3 x9-9/4" x6-1/2" 3x9-9/4" x8” 23SPEC} g™™| MAINTENANCE SPECIFICATIONS MAINTENANCE SPECIFICATIONS ENGINE Model Item Unit T9.9/F9.9A, F9.9/F9.9B CYLINDER HEAD: mm (in) 0.1 (0.004) Warp limit * Lines indicate straightedge measurement CYLINDER: Bore size mm (in) 59.00 ~ 59.02 (2.323 ~ 2.324) Wear limit mm (in) 59.1 (2.326) Taper limit mm (in) 0.08 (0.003) CAMSHAFT: Cam dimensions Intake "A" mm (in) 24.541 ~ 24.641 (0.966 ~ 0.970) Intake "B” mm (in) 20.137 ~ 20.237 (0.793 ~ 0.797) Exhaust "A" mm (in) 24.578 ~ 24.678 (0.968 ~ 0.972) Exhaust "B" mm (in) 20.178 ~ 20.278 (0.794 ~ 0.798) Camshaft runout limit mm (in) 0.1 (0.004) CAM BELT: ‘Cam belt type Coged belt Belt slack mm (in) 0 ~ 10 (0 ~ 0.4) 24SPEC) y™| MAINTENANCE SPECIFICATIONS QS Model tem Unit T9.9/F9.98 | _F9.9/F9.9B VALVE, VALVE SEAT, VALVE GUIDE: Valve clearance (cold): IN. mm (in) 0.15 ~ 0.20 (0.0059 ~ 0.0079) EX. mm (in) 0.20 ~ 0.25 (0.0079 ~ 0.0098) Valve dimensions ‘0 st a? t Head da aco width Seat with Margin thickness "A" Head dia. IN. mm (in) 25.9 ~ 26.1 (1.020 ~ 1.028) EX. mm (in) 21.9 ~ 22.1 (0.862 ~ 0.870) "B" Face width IN. mm (in) 198 ~ 3.11 (0.078 ~ 0.122) EX. mm (in) 198 ~ 3.11 (0.078 ~ 0.122) "C’ Seat width IN, mm (in) 0.6 ~ 0.8 (0.024 ~ 0.031) EX. mm (in) 0.6 ~ 0.8 (0.024 ~ 0.031) "D" Margin thickness IN. mm (in) 05 ~ 0.9 (0.020 ~ 0.035) EX. mm (in) 05 ~ 0.9 (0.020 ~ 0.035) Stem outside dia. IN. mm (in) 5.475 ~ 5.490 (0.2156 ~ 0.2161) EX. 5.460 ~ 5.475 (0.2150 ~ 02156) Guide inside dia. IN. 5500 ~ 5.512 (0.2165 ~ 02170) EX. 5,500 ~ 5.512 (0.2165 ~ 0.2170) Stem-to-guide clearance IN. mm (in) 0.010 ~ 0.037 (0.0004 ~ 0.0015) EX. mm (in) 0.025 ~ 0.052 (0.0010 ~ 0.0020) Stem runout limit mm (in) 0.016 (0.0006) 25SPEC} U"™| MAINTENANCE SPECIFICATIONS QS Model uw a T99/F9.9A F99/F9.98 VALVE SPRING: Set length (Valve closed) IN mm (in) 24.4 (0.96) Ex. mm (in) 24.4 (0.96) Compressible forth IN. N(kg,1b)| 90 ~ 100 (9.0 ~ 100, 19.8 ~ 220) (installed) EX, N(kg,lb)| 90 ~ 100 (9.0 ~ 100, 19.8 ~ 220) Tilt iit? : IN, mm (in) 1.1 (0.043) EX. mm (in) 134 (0043) Direction of winding IN Left hand EX. Left hand PISTON: Piston to cylinder clearance mm (in) 0.035 ~ 0.065 (0.0014 ~ 0.0026) Piston side “D" mm(in)| 58.950 ~ 58.965 (2.3209 ~ 2.3215) Measuring point “H” mm (in) 10 (0.39) Overside ist mm (in) 59.25 (2.333) 2nd mm (in) 59.50 (2.343) PISTON RING: “Top ring: Type 3 Plain (Barrel face) Dimensions (8 XT) mm (in) 115 X23 (0.06 x 0009) End gap (Installed). > mm (in) 0.18 ~ 0,30 (0.006 ~ 0.012) Limit mm (in) 0.50 (0.020) Side clearance (Installed) rm (in) 0.04 ~ 0.08 (0.002 ~ 0.003) 2nd ring: Type Plain (Taper face) Dimensions (8 xT) 8 | mm (in) 1.5 X24 (0.06 X 0.09) End gap (Installed) mm (in) 0.15 ~ 0.30 (0.006 ~0.012) Limit —r. mm (in) 0.50 (0.020) one clearance (Installed) mm (in) 0.03 ~ 0.07 (0.001 ~0.003) i ring: Dinersions(6 x1) [rads mm (in) 24 x25 (009 X0.10) End gap (Installed) [5] mm (in) 0.20 ~ 0.70 (0.008 ~ 0.028) CONNECTING ROD: Oil clearance (Big end) mm (in) 0.021 ~ 0.045 (0.0008 ~0.0018) 26SPEC| yg | MAINTENANCE SPECIFICATIONS QS Model ttem Unit T9.9/F9.9A F9.9/F9.9B CRANKSHAFT: 9 B aT] al Crank width “A” ‘mm (in) 123.7 ~ 123.9 (4.87 ~ 4.88) Runout limit “B” mm (in) 0.02 (0.0008) Main bearing clearance mm (in) 0.005 ~0.043 (0.0002 ~ 0.0017) Crankcase mark-Bearing color A-Blue, B-Black, C-Brown CARBURETOR: ‘Stamped mark 6G805 6G905 Main Nozzle mm (in) 2.2 (0.087) Main Jet (MJ) # 86 Pitot jet Pa) + 4 Pilot screw (turn out) (P.S.) ‘Turns Sit Valve seat size ws) mm (in) 41.2 (0.047) Float height” mm 25541 (in) (10.04) Idling speed rpm 1,150+50 950+50 Trolling speed rpm 1,000 +50 850450 THERMOSTAT: Valve opening temperature “C(F) 58~62 (136~144) Full open temperature “C(F) 70 (158) Valve lift (at full open temp.) mm (in) | 3.(0.12)SPEC] y™| MAINTENANCE SPECIFICATIONS Inner rotor to outer Ge rotor © Rotor to housing " © Relief valve operating pressure 0.02 ~ 0.15 (0.0008 ~ 0.0059) 0.05 ~ 0.07 (0.0020 ~ 0.0028) 388 ~ 450 (8.88 ~ 4.50, 55.19 ~ 64.00) (<3) Model tem Unit oe 19,9/F9.9A F9.9/F9.9B FUEL PUMP: ‘Consumption 2 7h, rpm Min 18.9, 2,750 Diaphragm stroke mm (in) 2.4 (0.0945) Plunger stroke mm (in) 5.8 (0.2289) LUBRICATION SYSTEM il filter type: \ Stee! mesh il pump type: ») Torochoid type Outer rotor to cy} | mm ory 0.06 ~ 0.11 (0.0024 ~ 0.0043) housing @ | 28SPEC] Us| MAINTENANCE SPECIFICATIONS e ELECTRICAL Model a a TO9/FO9A | F99/F99B IGNITION SYSTEM: Ignition timing (at full retarded) Degress *BTDC 543 Ignition timing (at full advanced) Degress “BTDC 3543 Piston position (at full advanced) mm (in) 4.78£0.76 (0.188 +0.030) Charge coil resistance at 20°C (68°F) Q 280 ~ 420 (Brown-Blue) Pulser coll resistance at 20°C (68°F) 2 168 ~ 252 (White/Red-Black) Ignition coil resistance at 20°C (68°F) primary wire Q 0.08 ~0.11 (Orange-Black) secondary wire Ko 3.49 ~ 472 (High tension cord-High tension cord) Saprk plug gap \m (in) 06 ~ 07 (0.024 ~ 0.028) *: Before top dead center CDI unit resistance chart NOTE: 4. Digital multimeter can not be used for inspection. Use analogue tester. 2, CDI resistance values will vary from meter to meter, especially with electronic digital meters. For some testers, polarity of leads is reversed. Unit: ko 3 a T Wn = Ww © 3 42 42 25 sort | 4622 “e “3 ar +500 Fo +500 Fie +i50 | Fe 5007590 ro00g, | s00*500 | etl 150° 15 asirasn) us 70735 (9.9/F9.98) T wzet28 | wg FO woFT | epg F80 Te 26728 | +7079 70770 | +9080 WR TEs +18 +15 +20 +16 ve wt? ttf 2020 16th ° +800 | —B0=10 += +500 +200 | r= 500-7250 10007550 | 500350 200-100, (19.9/F898) ‘oo 100 (F0.9/F998) Ww. = a 5 = = o 42 +i +1 +18 +20 +18 1a t rr wstf5 | 20 13 —~ B: Black Br: Brown L: Blue W/R: White/Red P: Pink W: White O: Orange ze: Discontinuity. 29 *: Needle swings once and returns to home position.SPEC] y™| MAINTENANCE SPECIFICATIONS 2 - Model tem a T99/FO9A FO9/F9.9B Lighting coil 2 091 ~ 1.37 073 ~1.09 (Green-Green) (Green-Green) 0.96 ~ 1.44 (White/Green-Black) Electrothermal valve Electrothermal valve resistance Q 48~72 at 20°C (68°F) Valve heater coil resistance Q 0.24 ~ 0.36 at 20°C (68°F) Starter-motor Rating Sec Output kW Clutch type Brush length mm (in) 9.0 ~ 125 (0.35 ~ 0.49) mm (in) 9 (0.35) ‘Commutator under cut mm (in) 02 ~ 0.8 (0.01 ~0.03) mm (in) 0.2 (0.01) Commutator diameter mm (in) 290 ~ 30.0 (1.14 ~ 1.18) ‘mm (in) 29 (1.14) Others Fuse A 20 210SPEC| Us| MAINTENANCE SPECIFICATIONS DIMENSION Model ‘Symbol (Used in diagram) Unit T9.9/F9.9A F9.9/F9.9B H4 s mm (in) 482 (17.0) L mm (in) 559 (22.0) ub mm (in) 635 (25.0) = B13 mm (in) 114 (45) B14 mm (in) 126 (5.0) ct mm (in) 33 (1.3) c2 mm (in) 65 (26) anSPEC] gy] MAINTENANCE SPECIFICATIONS e TIGHTENING TORQUE T - ”,. [Tightening torque Pert to be mend | Part name | Threed ae | Oty na a ne] Remarks ENGINE: 1st 6 [06 [43 Connecting rod |") Bolt M6 seer a 1st | Bon Me 5-8 [08 [43] ig a 2nd 12 | 12 | 87 1st | Bot mi 2 eps ttl g 2nd 30_| 30 | 22 ist 16 [15 | 1 Cylinder head aa} Bol Ms 6 Sale| a Oil element assembly = M24 1 | 8 | 08 | 58 Exhaust cover Bolt M6 7 | 12 | 12 | 87 Rock arm adjusting screw | Lock nut M5 4 | 8 | 08 | 58 Drive gear Nut maa | 1 | 2 | 23 | 7 Driven gear Bott M6 1 [13 [43 [94 Fiywhool Nut M12 1 | 100 | 100 | 72 |=) ‘Spark = M10 2 [13 [13 | 94 Engin mounting Bolt M8 6 | ai | aa | 15 UPPERCASE AND GEAR CASE: Pinion nut Nut Ms 1 | 26 | 26 | 19 | Exhaust guide mounting | Bolt M6 2 | 10 | 10 | 72 Relief valve = M14 1 | 8 [os | sa | Bracket bolt Nut 1 [ar [ar |e Steering bracket Bolt [2 [3 [13 | 94 [=e Upper side mount rubber | _Nut 2 | 25 | 25 | 18 Propeller Nut M10 1 [13 [13 [94 Plug drain = Mi8 1 [8 [08 | 58 Manifold exhaust mounting Bolt M6 2 [12 | 12/87 Bottom cowing mounting Bolt Ms | 6 | a jai| 15 General torque Nut (A) | Bolt (B) | Specifications Nm_[ nekg | ft tb ‘mm Ms 50 | 05 | 36 10 mm Me 20 | 08 | 58 12mm Me te | 18 | 13 14mm mio | 36 | 36 | 26 17mm wiz | 43 | 43 | 31 242 GENERAL TORQUE SPECIFICATIONS This chart specifies the torque for tightening standard fasteners with standard clean dry ISO threads at room temperature. Torque specifications for special components or assemblies are given in applicable sections of this manual. To avoid causing warpage, tighten multifastener assemblies in crisscross fashion, in progressive stages until the specified torque is reached.INSP Q ADJ CHAPTER 3 PERIODIC INSPECTION AND ADJUSTMENT PREDELIVERY SERVICE... CONTENTS .. PACKING LIST ........ ELECTRICAL WIRING... . FUEL LINE AND PIPING ENGINE OIL LEVEL GEAR OIL LEVEL . 5 OPERATION OF CONTROLS AND MOVING PARTS. FUEL LEAKAGE .. WATER LEAKAGE EXHAUST LEAKAGE . ENGINE AND LOWER UNIT NOISE - IDLE-SPEED ... IGNITION TIMING : eobedagy OIL PRESSURE INDICATOR «<0... cccsssscseee MOTOR EXTERIOR INSTRUCTING THE NEW OWNER PERIODIC SERVICE MAINTENANCE SCHEDULE. ANODE... PROPELLER, BATTERY . ENGINE OIL LEVEL CHECK. ENGINE OIL REPLACEMENT GEAR OIL LEVEL CHECK GEAR OIL REPLACEMENT .. SPARK PLUG TIMING BELT . VALVE CLEARANCE ADJUSTMENT . SHIFT CABLE ADJUSTMENT STARTN GEAR PROTECTION ADJUSTMENT... NEUTRAL OPENING LIMIT ADJUSTMENT PILOT SCREW ADJUSTMENT . IDLE SPEED ADJUSTMENT . THROTTLE LINK ADJUSTMENT .. THROTTLE CABLE ADJUSTMENT IGNITION TIMING CHECKINSP ADJ Q PREDELIVERY SERVICE >) PREDELIVERY SERVICE CONTENTS Htem| Refer to page 1. Packing list a4 2. Electrical wiring 92 ~ 35 3, Fuel line and piping 36 4, Engine oil level 37 5. Gear oil level 37 6. Operation of controls and moving parts 37 7. Fuel leakage 38 8. Water leakage 38 8. Exhaust leakage 38 10. Engine and lower unit n 38 11. Idle speed 38 12. Ignition timing 38 18. Oil pressure indicator 38 14. Motor exterior 38 16. Instructing the new owner 38 PACKING LIST Model | T99MH | T99EH | T99ER | F99MH Packing name F9.9AM |F99AEM| F99AE | Fa9pM |*?°BEM| F99BE Outboard motor ° ° ° ° ° ° Fuel tank ° ° ° ° ° ° Service tools o" | oO o* | oF ° ° Emergency starter rope ° ° ° ° ° ° Motor mounting parts ° ° ° = - = Steering guide attachment - - oz | — - - Spare spark plugs o* | ot | ot | ot | 0 ° ‘Owner's manual ° ° ° ° ° ° Remote control = = ° = - ° Indicator panel - - ° = = ° Except for USA. model *2: For USA and CANADA model 34INSP ADJ Qa PREDELIVERY SERVICE a> ELECTRICAL WIRING Check that all leads and connectors are properly connected. ‘T9.9MH/F9.9AM, F9.9MH/F9.9BM Lighting coil Ground Pulser coil/Charge coil Cit-pressure switch Rectifier regulator Ground CDI unit Ignition coil CDI unit Engine stop switch Oil-pressure indicator-lamp Electrothermal valve SSSOSQGESOGO WIR: White/Red Br: Brown Blue Black White Pink Yellow/Red Green Orange Green/White RedINSP ADJ @ PREDELIVERY SERVICE ‘T9.9EH/F9.9AEM, F9.9BEM Lighting coil Ground @® Fuse holder @ Fuse holder © Pulser coil/ Charge coil Oil pressure switch @® Rectifier regulator ® Ground ® coiunit ® grition coi @ CDI unit ® Engine stop switch ® Oitpressure indicator-amp @ Starter-switch ® Starter relay Electrothermal valve W/R: White/Red Br: Brown Blue Black White Pink Yellow/Red Green Orange Green/White Red Black/WhiteINSP ADJ Q PREDELIVERY SERVICE <> T9.9ER/F9.9AE Lighting coil Ground Fuse holder Fuse holder Pulser coil/ Charge coil Oil-pressure switch Rectifier regulator Ground CDI unit Ignition coil @® CDI unit ® Wiring-harness Starter relay @ Electrothermal valve 'BO@@QOE@SOOO W/R: White/Red Br: Brown L: Blue B: Black W: White P: Pink Y/R: Yellow/Red G: Green ©: — Orange G/W: Green/White R: Red B/W: Black/White a4 Y: YellowINSP ADJ PREDELIVERY SERVICE QS F9.9BE @ Lighting coil ® Ground @ Fuse holder @ Fuse holder © Pulser coil/Charge coll © Oitpressure switch © Rectifier regulator ® Ground © col unit @® ‘gnition coil ® CDI unit ® Wiring-harness @ Starter relay ® Electrothermal valve 35 : White/Red Br: Brown L Blue B: Black W: — White P: Pink Y/R: Yellow/Red G Green 0: — Orange G/W: Green/White R: Red B/W: Black/White Y: YellowINSP ADJ Q PREDELIVERY SERVICE & FUEL LINE AND PIPING Check that the fuel line is correctly installed. © Fuel joint @ Fuel strainer @ Fuel pump @ Oil separator © Carburetor © Thermostat cover 36et @Q | prevetivery service QS 7 ENGINE OIL LEVEL Remove the oil level gauge and check so the oil level should be between F and L. Fill the oil if necessary. NOTE: Be sure the outboard motor is positioned straight up when inspecting the oil level. Recommended oil: ‘SAE: 10W-30, 10W-40 API: SE, SF, SESF, SESF-CC, SG-cD GEAR OIL LEVEL Remove the oil-drain plug @ and oil-level plug @,andadd the gear oil through the oil-drain hole Until it over flows from the oil-level hole. Refit the plugs. (The oil level plug first.) NOTE: Be sure the motor positioned straight up when checking the oil level. OPERATION OF CONTROLS AND MOV- ING PARTS 1. Check shift control for normal operation. 2. Check tilt-lock mechanism for normal operation. 3.Check steering control for smooth operation, 4, Check throttle control for smooth operation. 5.Check remote control lever for smooth operation. 6. Check ignition timing for normal operation. 7. Check cowling lock and release mechanism for normal operation. 8. Check starting system for normal operation. AWARNING Before attempting to check the starting system, replace the propeller with the specified test propeller, and install the motor in a test tank. 9. Check for normal operation of the engine stop system. 37INSP ADJ PREDELIVERY SERVICE eS FUEL LEAKAGE Check for fuel leakage. WATER LEAKAGE Check for water leakage. EXHAUST LEAKAGE Check for exhaust leakage. ENGINE AND LOWER UNIT NOISE Check the engine and lower unit for abnormal noise. IDLE-SPEED Check that the engine speed at fully-closed throttle is correct. Refer to page 2-1, 2-2. IGNITION TIMING Check that the ignition timings at fully-closed and fully-open throttle positions comply with the specifications. Refer to page 2-9. OIL PRESSURE INDICATOR Check the oil pressure indicator is turned on when the engine started. MOTOR EXTERIOR Check the motor exterior for any flaking of the paint, and if necessary touch-up with paint of the original colour. INSTRUCTING THE NEW OWNER Instruct the new owner on the operation of all controls and the break-in procedure. Also ad- vise him on propeller-to-boat matching. 38INSP ADJ Qa PERIODIC SERVICE eS PERIODIC SERVICE MAINTENANCE SCHEDULE The following chart may be taken as a helpful guide to the intervals between maintenance procedures. Teal Every "tem Sonouws | 100hous | 200 hours (months) | (Gmenths) | (1 year) ‘Anode ° oO ° 38 Battery ° 3410 + month) Bolts and nuts ° ° - Carburetor ° ° = Gooling water passages ° ° = Engine oll ° ° 312 Fuel strainer ° ° ° = Fuel tank ° = Gear oil ° a4 Greasing points ° = Idle speed ° 322 Ignition timing ° ° 324 Oilfiter ° ° 313 ° ‘Outboard motor body ° ° = Propeller ° ° 340 Spark plug ° ° 345 Timing bet ° 316 Thro link ° ° 322 Valve clearance ° ° 347 ANODE 1. Inspect: + Anode Wear/Damage —» Replace. CAUTION: Do not paint the anode, or the outboard may be corroded. 2. Clean: + Anode Use a wire brush. NOTE: Remove all race of oil or grease. After cleaning, polish the contact surfaces of the anode mount, and re-install, CAUTION: Never paint the anode. To ensure good electrical contact, keep the anode contact surface clean of oil or grease.INSP ADJ @ | perionic service QS PROPELLER 1. Inspect: + Propeller + Spline Wear/Damage —- Replace. 5 BATTERY CAUTION: — Be careful not to place the battery on its side. Before adding the battery fluid or recharging, be sure to bring it out of the engine compartment. When checking the battery, make sure the breather pipe is connected to the battery and is not pinched shut in any part of the engine compartment. Battery electrolyte is poisonous and danger- ‘us, causing severe burns, etc. Contains sulfuric acid. Avoid contact with skin, eyes or clothing. Antidote: EXTERNAL-Flush with water. INTERNAL-Drink large quantities of water or milk. Follow with milk of magnesia, beaten egg or vegetable oil. Call physician immedi- ately. Eyes: Flush with water for 15 minutes and get prompt medical attention. Batteries produce explosive gases. Keep sparks, flame, cigarettes, etc., away. Ventilate when charging or using in enclosed space. Always shield eyes when working near batteries. KEEP OUT OF REACH OF CHILDREN. 1. Inspect: + Battery fluid level Battery fluid level low — Fill distilled water. Fluid level should be between upper @ and lower @ level marks. CAUTION: +Disconnect the negative black lead © to the battery terminal first. Water other than distilled water contain minerals which are harmful to a battery; top up only with distilled wat 3.10INSP ADJ PERIODIC SERVICE > Recommended battery capacity: 12 V 70 AH (252 kC) Filling steps: + Remove each filler cap using a pliers. + Fill with distilled water using a jug. NOTE: Use an acid jug or bottle with a 5 mm (0.2 in) or smaller dia nozzle @. If the acid jug has too large of a nozzle diameter, use a tapered tip funnel, during filing, do not cover the filler ‘opening @ completely; leave room for escap- ing air and gases. *After the acid is filled up to the UPPER LEVEL, allow the cell to stand for 20 minutes. IF the acid level has dropped, add the same acid upto the UPPER LEVEL once again. 2. Check: + Battery fluid specific gravity Out of specification — Charge. A Specific gravity at 20°C (68°F): 1.28 Charging current: 7.0 amps/10 hrs 8. Install «Filler cap ©) + Filler opening @) NOTE: + After charging, securely push the filler caps in the filler openings. + Rinse off any acid from the battery case and wipe the battery dry prior to installation. anINSP ADJ PERIODIC SERVICE <> CAUTION: +Connect the positive red lead © to the battery terminal first. +Make sure battery leads are connected properly. Reversing leads can seriously damage the electrical system. +Make sure the breather pipe is properly connected and is not obstructed. + Coat the terminals with a water resistant grease to minimize terminal corrosion. 4. Inspect + Battery terminal Dirt + Clean with wire brush. Poor connection + Correct. NOTE: After cleaning the terminals, apply grease lightly to the terminals. ENGINE OIL LEVEL CHECK 1, Place the outboard motor in an upright position. 2. Check: + Engine oil level Oil level should be between the maximum F and minimum L marks. Oil level is low-+Add oil to proper level. IN’) Recommended oit: ‘SAE: 10W-30, 10W-40 API: SE, SF, SESF, SESF-CC, sG-cD ENGINE OIL REPLACEMENT 1. Place the outboard motor in an upright position. 2. Place a suitable container under the outboard motor. 312INSP ADJ PERIODIC SERVICE 343 8. Remove: + Oil filler cap + Drain bolt Drain the engine oil. 4, Remove: + Oil filter assembly D 5. Inspect: +Oil filter element D Damage —+ Replace. Foul/Clog —> Clean. 6. Clean: + Oil filter element Blow out dust in the element from the outer surface using compressed air. + Drain boit © “Oil filter assembly (2) Drain bolt: 8Nm (0.8 m-kg, 5.8 ft-Ib) Oil filter assembly: &8Nm (0.8 m-kg, 5.8 ft-Ib)INSP ADJ PERIODIC SERVICE ce 8. Fill: + Engine oil Recommended oi ‘SAE: 10W-30, 10W-40 API: SE, SF, SESF, SESF-CC SG-CD Oil capacity: 4.02 (1.08 US qt, 0.88 Imp a) 9. Check: + Engine oil level Refer to page 3-12, 10. Install: Oil filler cap GEAR OIL LEVEL CHECK 1. Place the outboard motor in an upright Position. 2. Check: + Gear oil level Oil level is low > Add oil to proper level. Checking steps: + Remove the oil drain and oil level plugs. +/Add the gear oil through the oil drain hole until it over flows from the oil level hole. Np] Recommended oft: Hypoid gear oil (SAE 90) + Install the oil level plug. + Install the oil drain plug. GEAR OIL REPLACEMENT 1.Place the outboard motor in an upright position, 2. Place a suitable container under the outboard motor. 3. Remove: + Oil drain plug + Oil level plug 34 Drain the gear oilINSP ADJ Q PERIODIC SERVICE 4. Fill: + Gear oil xp Recommended oil: Hypoid gear oil (SAE 90) Oil capacit T9.9/F9.9A: 320 cm* (10.82 us oz, 11.26 Imp 02) F9.9/F9,9B: 185 cm? (6.25 us 02, 6.51 Imp 0z) 5. Check: + Gear oil level 6. Install: + Oil level plug + Oil drain plug SPARK PLUG 1. Remove: + Spark plug 2. Inspect: + Electrode ® Wear/Damage —> Replace. + Insulator color Q) Normal condition is a medium to light tan color. Distinctly different color —> Check the engine condition Whitish color: Lean fuel mixture * Plugged filter, jet * Air leak * Wrong settings Blackish color: Electrical malfunction Defective spark plug 3, Clean: + Spark plug Clean the spark plug with a spark plug cleaner or wire brush. 4, Inspect: * Spark plug type Incorrect —> Replace. Standard spark plug: NGK CR6HS 315INSP ADJ PERIODIC SERVICE HL Jee + 5. Measure: + Spark plug gap @ Out of specification — Regap. Use a wire gauge. a 6. Tighten: + Spark plug NOTE; Before installing a spark plug, clean the gasket surface and plug surface. Also it is suggested to apply a thin film of Anti Seize Compound to the spark plug threads to prevent future thread seizure. Spark plug gap: 0.6 ~ 0.7 mm (0.024 ~ 0.028 in) 316 Spark plug: 13 Nm (1.3 mvkg, 9.4 ftlb) Ei NOTE: Ifa torque wrench is not available when you are installing a spark plug, a good estimate of the correct torque is 1/4 to 1/2 turns © part finger tight @ . Have the spark plug torqued to the correct valve as soon as possible with a torque wrench. TIMING BELT 1. Inspect: + Timing belt Wear/Damage -+ Replace. 2. Check: + Timing belt slack @ Push the timing belt with your finger. Out of specification —- Replace. Timing belt siacl 0 ~ 40 mm (0 ~ 0.4 in)el Q PERIODIC SERVICE eS VALVE CLEARANCE ADJUSTMENT NoTe: +The valve clearance must be adjusted when the engine is cool to the touch. + Adjust the valve clearance when the piston is at the Top Dead Center (T.D.C) on compression stroke. 1, Remove: *ScrewD +Hinge pin @ + Flywheel cover @) 2. Remove: + Bolt © +Clamp lever @ 3. Remove: Hose + Bolt @ Cylinder head cover @ 4, Measure: + Valve clearance @ Out of specification — Adjust. Valve clearance (cold): Exhaust: 0.20 ~ 0.25 mm (0.0079 ~ 0.0098 in) 317INSP ADJ PERIODIC SERVICE ce) Measurement steps: + Tum the crankshaft clockwise. + Align the “1” on the driven gear @ with the mark on the cylinder head @) when #1 piston is at TDC on compression stroke. NOTE: + When measuring the valve clearance at the #2 cylinder, turn the driven gear 180° so that the “2” marked on the driven gear aligns with the mark on the cylinder head. + Measure the valve clearance using a feeler gauge ®. 5. Adjust: + Valve clearance ‘Adjustment steps: + Loosen the lock nut ®. + Insert the specified feeler gauge @ into the clearance between the valve stem end and the adjust bolt. + Adjust the adjust bolt using a valve adjuster © SF Valve adjuster YM-08035/90890-01311 * Tighten the lock nut with the feeler gauge inserted. Na Lock nut: 8. Nm (0.8 mkg, 5.8 ftb) NoTi Lock the adjust bolt so that it does not move. 318INSP ADJ PERIODIC SERVICE 319 6. Measure: + Valve clearance Out of specification + Readjust. NOTE; If too loose or too tight, readjust the valve clearance. 7. Apply: + Engine oil To valve stem and adjust bolt. 8. Install: +Seal + Cylinder head cover ® +Bolt @ Hose © Install: + Clamp lever © +Bolt @ 10. Install: + Flywheel cover @ +Hinge pin @ + Collar + Screw @INSP ADJ PERIODIC SERVICE SHIFT CABLE ADJUSTMENT 1. Adjust: + Shift cable length Adjustment steps: + Loosen the lock nut ©. +Remove the cable end @. *Set the shift lever to neutral. +Set the shift arm to neutral. + Tum the cable end in or out until adjustment is suitable. “Fit the cable end to the pin marked with “M” on the shift arm, «Push the cable end stopper @ to secure the cable end. «Tighten the lock nut. 3:20 START-IN GEAR PROTECTION ADJUSTMENT gear protection operation Incorrect —+ Adjust. 2. Adjust: + Startin gear protection cable length ‘Adjustment steps: + Sot the shift lever to neutral. + Remove the hinge pin and throw down the front panel (. + Loosen the lock nut @. “Adjust the adjuster @) so that the arrow marks @ on the lock arms @) align with each other. + Tighten the lock nut.ABS Q PERIODIC SERVICE é& NEUTRAL OPENING LIMIT ADJUSTMENT 1. Check: + Neutral opening control operation Incorrect —+ Adjust. 2. Adjust: + Accelerator arm position. ‘Adjustment steps: Attach the tachometer. ‘Tachometer: ‘YU-8036-A/90890-06760 + Set the shift lever to neutral. + Start the engine. + Tum the throttle grip so that the engine speed is specified. Engine speed: © | aa00250 pm * Loosen the bolt @. + Contact the accelerator arm @ and shift rod link @. ten the bolt. PILOT SCREW ADJUSTMENT 1. Adjust: +Pilot screw Adjustment steps: *Screw in the pilot screw @ until it is lightly seated. ‘Back out by the specified number of tums. Pilot screw: 3:1 tums out 321INSP ADJ PERIODIC SERVICE 2 IDLE SPEED ADJUSTMENT 1. Start the engine and let it warm up. 2. Attach: *Tachometer To spark plug lead. Tachometer: ‘YU-8036-A/90890-06760 3. Measure: Idle speed Out of specification—-Adjust. (| Isle speed: ‘T9.9/F9.9A: 1,150 + 50 rpm F9.9/F9.9B: 950 + 50 rpm 4, Adjust: «Idle speed ‘Adjustment steps: + Turn the throttle stop screw specified idle speed is obtained. Turning in —+ Idle speed becomes higher. ‘Turning out —> Idle speed becomes lower. or out until NOTE: After adjusting the engine idle speed, the throttle link should be adjusted. 322INSP ADJ Q PERIODIC SERVICE <> THROTTLE LINK ADJUSTMENT NOTE: ——— Engine idling speed should be adjusted properly before adjusting the throttle link. 1. Check: + Full-open position Incorrect > Adjust. Checking steps: + Pull the accelerator arm @ to the full-open side. + Check the throttle lever @ to the full-open Position. 2. Adjust: + Throttle link length Adjustment steps: Loosen the lock nut @. + Tur the adjust nut @ in or out until adjustment is suitable. “Tighten the lock nut. 3. Check: + Throttle link free play @ No free play + Replace the throttle link. Checking steps: +Push the accelerator arm @ to the full- closed side. +Make sure the throttle lever is on the {ull-closed position. + Check that the throttle link @ has free play on the throttle lever side.INSP ADJ PERIODIC SERVICE > 3.24 THROTTLE CABLE ADJUSTMENT NOTE: Engine idle speed and throttle link should be adjusted properly before adjusting the throttle cable. 1. Check: + Full-open position Incorrect —- Adjust. Checking steps: + Tum the throttle grip to the full-open side. «Check the throtte lever @ to the full-open position. 2. Adjust: + Throttle cable length ‘Adjustment steps: + Loosen the lock nut ©. + Remove the cable end @. +Pull the accelerator arm to the full-open side. + Tum the cable end in or out until adjustment is suitable. *Fit the cable end to the pin marked with “MI on the accelerator arm. + Push the cable end stopper @) to secure the cable end. «Tighten the lock nut. IGNITION TIMING CHECK NOTE; Ignition timing is advanced by the CDI unit automatically. Therefore only the checking procedure is shown in this section.INSP ADJ PERIODIC SERVICE (<>) 4. Attach: *Tachometer +Timing light To spark plug lead for #1 oylinder. Tachometer: ‘YU-8036-A/90890-06760 Timing light: YU-39277-A/90890-03141 2. Checl + Ignition timing Incorrect firing range > Check flywheel and/or pickup assembly. Checking steps: + Warm up the engine and setitat the specified speed, O)| Ensine speec: T9.9/F9.9A: 1,150 +50 rpm F9.9/F9.9B: 950 +50 rpm + Direct the timing light toward the flywheel magneto base ®. + Visually check the stationary pointer @ to verity itis within the required firing range @) indicated on the flywheel. 3.25FUEL | fh) @Q CHAPTER 4 FUEL SYSTEM FUEL SYSTEM .. a PREPARATION FOR REMOVAL REMOVAL POINTS Diaphragm INSPECTION .. Fuel joint ..... Fuel strainer... Fuel pump ASSEMBLY AND INSTALLATION .... Fuel pump ... CARBURETOR . PREPARATION FOR REMOVAL . NOTE ON REMOVAL AND REASSEMBLY . REMOVAL POINTS Joint . INSPECTION nnsnnnnsnnnnninannnin Carburetor body ... Pilot scrow Jet and nozzle Needle valve Float ... Diaphragm Filter ‘Check vaive .... Electrothermal valve ASSEMBLY AND INSTALLATIONFUEL | fh) FUEL SYSTEM FUEL SYSTEM PREPARATION FOR REMOVAL * Remove the top cowling. WGN) + Gasoline (petrol) highly flammable and explosive. Handle with special care. + Failure to check for fuel leakage may result in fire or explosion. Extent of removal: @ Fuel joint removal @ Fuel pump disassembly @ Fuel pump removal Extent of renoval_| Order Part name oy Remarks oO 1 [Bok 7 2 | Fuel joint 1 | Disconnect the hose. 3. | Fuel strainer 1 | Disconnect the hose. 4 | Screw 2 @ 5 _| Fuel pump 1_| Disconnect the hose. 6 | Screw 4 7 | Bump body 1 8 | Diaphragm 1 9 1 10 1 11] Diaphragm spring 1 12 | Screw 2 13. | Plate 5 14 | Check valve 1 18_| Pump cover 4FUEL B® FUEL SYSTEM e REMOVAL POINTS DIAPHRAGM 1. Remove: + Diaphragm © CAUTION: — Push the plunger and hold the plate @, turn the diaphragm 90°. INSPECTION FUEL JOINT 4, Measure: . + Fuel joint operation Impossible to maintain the specified pressure for 10 sec. —- Replace. Uva AY, Measuring steps: \ *Attach the Mity Vac. A Mity Vac: YB-35056 / 90890-06756 + Apply the specified pressure. AA Specified pressu 50 kPa (0.5 kg/em®, 7-1 psi FUEL STRAINER 1. Inspect: + Fuel strainer on) Crack/Leak/Clog -» Replace. FUEL PUMP 1. Inspect: Check valve @ + Diaphragm @ Damage —> Replace. 42FUEL FUEL SYSTEM 2. Inspect: = Spring © + Diaphragm spring @ Damage —> Replace. ASSEMBLY AND INSTALLATION FUEL PUMP 1. Install +Pump body @ + Diaphragm spring @ + Spring @ + Plunger © NOTE: ss Align the recess in the plunger with the pump body. 2. Install: Diaphragm D CAUTION; ——____ Push the plunger and hold the plate @, then turn the diaphragm 90°. 3. Install: + Pump cover © + Check valve @ +Plate@ +Sorew @ NOTE: _—______—_ Align the recess in the check valve and plate with the projection of the sump cover. 43FUEL FUEL SYSTEM 4. Install: «Pump body @ +Pump cover @) +Screw @ NOTE: After installing, check the smooth movement of the plunger. 5. Measure: + Fuel pump operation Impossible to maintain the specified pressure for 10 sec. —+ Replace. Measuring steps: Attach the Mity Vac to the inlet of the fuel pump. LW Mity Va YB-35956 / 90890-06756 + Cover the outlet of the fuel pump. + Apply the specified pressure. Specified pressu 50 kPa (0.5 kg/cm?, 7.1 psi) 6. Measure: + Fuel pump operation Impossible to maintain the specified pressure for 10 sec. — Replace. Measuring steps: + Attach the Mity Vac to the outlet. A Mity Vac: YB-35956 / 90890-06756 + Apply the specified pressure. 44 ‘Specified pressure: 50 kPa (0.5 kg/cm, 7.1 psi) 7. Install: +O-ing © NOTE: Always use a new O-ring.FUEL wD FUEL SYSTEM 8. Install: + Fuel pump ® + Screw @) +Hose @ Hose @ +Clamp © 45FUEL B® CARBURETOR > CARBURETOR PREPARATION FOR REMOVAL * Remove the top cowling. + Gasoline (petrol) is highly flammable and * Disconnect the wire lead. explosive. Handle with special care. + Failure to check for fuel leakage may result In fire or explosion.| FUEL B® CARBURETOR eS NOTE ON REMOVAL AND REASSEMBLY + With the engine mounted, the following parts can be removed. + Before inspection, the removed parts should be cleaned and blow out all passages and jets with compressed air. + After removing the carburetor, cover the carburetor joint preventing foreign material from entering. Extent of removal: — @ Carburetor removal @ Carburetor disassembly @ Electrothermal valve removal Extent of removal [Order Part name Oty Remarks T [1 | Throttie tink 1 _| Disconnect the link lod. ® 2 | Funnel 1 3 | Nut 2 4 | Carburetor 1 5_| Screw 2 6 | Electrothermal valve 1 7 | Clip 1 8 | Screw 4 9. | Float chamber 1 10_| Pin 1 11 | Float 1 12 | Needle valve 1 13 | Screw 2 | | 14 | Cover 1 15_| Diaphragm 1 16 _| Filter i a7 REMOVAL POINTS JOINT 1. Disconnect: + Throttle link @ + Fuel hose @FUEL CARBURETOR 6 e INSPECTION CARBURETOR BODY 1. Inspect: + Carburetor body Crack/Damage —» Replace. Contamination —> Clean. AWARNING Protect your eyes with suitable safety spec- tacles or safety goggles when using compressed air. NOTE: + Use a petroleum based solvant for cleaning. Blow out all passages with compressed ai. + Never use a wire. PILOT SCREW 1. Inspect: Pilot screw Bend/Wear —+ Replace. JET AND NOZZLE 1. Inspect: + Main jet + Pilot jet + Check valve + Main nozzle Contamination — Replace. NEEDLE VALVE 1. Inspect: Needle valve Grooved wear —> Replace. 48FUEL Bw CARBURETOR FLOAT 1, Inspect: + Float - Crack/Damage — Replace. ‘ Xs y DIAPHRAGM 1. Inspect: «Diaphragm Damage —+ Replace. © + Filter Contamination —- Clean. Damage —- Replace. CHECK VALVE 1. Inspe 7 5 * Check valve Damage —- Replace. ELECTROTHERMAL VALVE. 1. Inspect: + Needle valve ® + Piston valve @ Wear/Damage —» Replace.FUEL Bp CARBURETOR QS 2, Measure: + Electrothermal vaive resistance Out of specification —- Replace. al Electrothermal valve resistance: Brack Brack 4.8 ~ 7.2 0 at 20°C (68°F) 3. Check: *Piston valve height @ No change~-Replace. Checking stey + Connect the 12 V battery. + Wait for several minutes. *Check the piston height. ASSEMBLY AND INSTALLATION 1. Install: + Float chamber ® + Spring @ + Diaphragm @ +Cover @ +Screw © 2. Install: *Pilot jet O + O-ring @ +Seal cap @ +Main nozzle @ NOTE: Position the nozzle so that the cutaway of the nozzle faces the intake manifold. 3. Install: + Screw @ =Main jet @ NOTE: Align the slit in the mai hole in the carburetor. nozzle with the screw 410FUEL CARBURETOR an 4. Install: + Needle valve © *Float @) NOTE: Install the valve into the float hinge. 5. Install: After installing, check the smooth movement of the float. 6. Measure: + Float height @ Out of specification —- Fold the tab ® to adjust float arm height. Float height: 25.5 +1 mm (1.00 +0.04 in) NOTE: The float should be resting on the needle valve, but not compressing the needle valve. 7. Install: + O-ring © +Drain screw @ + Gasket @ + Drain screw @CARBURETOR 8. Install: +Filter D *Check valve @) *Gasket @ +Float chamber @) + Screw @ 9. Install: + O-ring @ + Electrothermal valve @ +Plate @ + Screw @ 10. Install: *Spring D +Pilot screw @) +Seal cap @ NOTE: After placing the seal cap cn the pilot screw, fit it to the groove in the carburetor. 11. Adjust: *Pilot screw D ‘Adjustment steps: + Screw in the pilot screw until it is lightly seated. + Back out by the specified number of turns. Pilot screw: 3.41 tums out 12. Install: Rod @ Washer @ +Clip @ NOTE: Always use a new clip. 4an2FUEL Be CARBURETOR 13. Install: +Gasket O + Spacer @ + Washer @ +Nut @ 14, Connect: + Throttle link © «Fuel hose @ 15. Connect: +Wire lead @ 16. Install +Gasket @ +Funnel Q) +Screw @) 17. Adjust: «Idle speed Refer to page 3-22.[Powe POWER UNIT REMOVAL CYLINDER, PISTON AND CRANKSHAFT CHAPTER 5 POWER UNIT PREPARATION FOR REMOVAL ...... . NOTE ON REMOVAL AND REASSEMBLY ..... REMOVAL POINTS Starter grip .. Stop wire .... INSTALLATION .. Power u Recoil starter Battery lead . Flywheel cover PREPARATION FOR REMOVAL... - NOTE ON REMOVAL AND REASSEMBLY 57 REMOVAL POINTS .... Flywheel magneto .. Timing belt... Drive gear .. INSPECTION AND REPAIR Flywheel magneto Drive gear . Timing belt Thermostat ... Cylinder .. Piston = Piston clearance Piston pin Piston ring Crankshaft Crankshaft main bearing clearance Combination of crankcase and bearing Connecting rod oil clearance ASSEMBLY AND INSTALLATION Piston and connecting rod Cylinder and crankcase Exhaust cover Timing belt Oil pressure switch Thermostat Starter motor Flywheel magnetoPowa| @y CYLINDER HEAD, VALVE AND CAMSHAFT 5-23 PREPARATION FOR REMOVAL 5-23 NOTE ON REMOVAL AND REASSEMBLY 5.24 REMOVAL POINTS 5:24 Cylinder head . 5-24 Rocker shatt .. . 5-24 Driven gear wneinnnnne . 5-25 Valve : 5:25 INSPECTION AND REPAIR 5:26 Oil separator 5:26 Oil pump... Rocker shaft and rocker arm Valve lifter 5:27 Camshaft 5:27 Cylinder head ... 5:28 Valve 5.33 Valve SPtig nnn 5:34 ASSEMBLY AND INSTALLATION 5:35 il pump assembly . 5-35 Cylinder head . 5-35 Cylinder head cover 5-39 Intake manifold 5-39 Oil separator ..... 5-39 RECOIL STARTER 5-41 PREPARATION FOR REMOVAL 5-41 REMOVAL POINTS 5-42 Starter rope 5-42 Spiral spring 5-42 INSPECTION 5-43 Starter rope 5-43 Spiral spring 5-43 Sheave drum and starter housing ... 5-43 Pinion ... . 5-43 ASSEMBLY AND INSTALLATION . 5-44POWR G POWER UNIT REMOVAL 2» POWER UNIT REMOVAL PREPARATION FOR REMOVAL * Drain the engine oil. * Remove the oil level gauge. * Remove the top cowling. * Disconnect the stop switch leads. * Remove the terminal cover. * Disconnect the oil lamp lead. ‘A [21 Nm (2.1 mrkg, 15 ft) 61POWR eS POWER UNIT REMOVAL © NOTE ON REMOVAL AND REASSEMBLY + After removing the power unit, protect the lubricating system, including the oil pan and relief valve, from dust and dirt. Extent of removal: @ Power unit removal Extent of removal | Order Part name Qty Remarks 1 | Fuethose 7 2 | Blow by hose 1 3 Water hose 1 4 Water hose 1 5 Water hose 1 6 Screw 1 7 | Hinge pin 1 t 8 | Flywheel cover 1 9 Grip cover 1 Recoil starter model only 10 _| Starter grip 1} | Refer to “REMOVAL POINTS". 11 | Neutral starting device cable | 1 12 | Battery lead 1 | Electric starter model only Refer to page 3-10. 13 | Screw 2 14 | Apron 2 15_| Bolt 6 16 | Power unit 1 REMOVAL POINTS ‘STARTER GRIP 1, Remove: + Starter grip © NOTE: When removing the starter grip, pull out the starter rope and make a knot in the rope so that the rope is not pulled into the starter. STOP WIRE 1. Remove: + Lock nut + Start.in gear protection cable @) NOTE: ————— Do not remove the stop wire before removing the starter grip, or it is impossible to pull out the starter rope when removing it. 52POWR eS POWER UNIT REMOVAL INSTALLATION POWER UNIT 1. Apply: + Gasket maker Onto both face of the gasket. NOTE; Clean the contacting surface of crankcase. 2. Install: +Gasket © Dowel pin @ + Oxing © +Seal @ 3. Install: + Power unit D NOTE: ——— + If the crankshaft splines do not mesh with the drive shaft splines, turn the flywheel a little so that they can mesh. + Use care not to pinch the lead and pipe. 4, Install: +Bolt © Nx Bolt: 21 Nm (2.1 mkg, 15 ftb) 5. Install: Apron D + Screw @POWR POWER UNIT REMOVAL 64 6. Install: * Oil level gauge © 7. Connect: + Water hose + Water hose @) = Water hose (8) *Blow by hose @ * Fuel hose (6) RECOIL STARTER 4. Install: + Stop wire ® + Lock nut @ 2. Adju + Start-in gear protection cable length Refer to page 3-20. 3. Install: + Starter grip © NOTE: ————————— Pass the starter rope through the front panel and starter grip, and make a knot in the end of the rope, then put it into the starter grip. 4. Install: *Grip cover © NOTE: = After installing the grip cover, untie the knot, and let the rope wind around the starter.POWR' POWER UNIT REMOVAL eS BATTERY LEAD 1. Install «Battery lead O Refer to page 3-10. NOTE: Connect the battery lead to both of the starter motor and starter relay. FLYWHEEL COVER 4. Install: * Grommet ©) Collar @ + Flywheel cover @ ‘Hinge pin @ + Screw ® NOTE: ——————— Secure the L-shaped portion to the holder. 2. Install: + Electrical leads + Terminal cover + Screw Refer to page 3-2 ~ 3-5. 3. Connect: + Throttle link @ 4, Adjust: + Throttle link length Refer to page 3-23. 55POWR, CYLINDER, PISTON AND CRANKSHAFT <>) CYLINDER, PISTON AND CRANKSHAFT PREPARATION FOR REMOVAL * Remove the power unit. Remove the following parts: + CDI unit + Ignition coil + Rectifier regulator et 15 Nm (1.5 mm 2nd: 30 Nm (8.0 mkg, 23 ftb) 100 Nm (10 rg, 72 ftib) A 3 c DPOWR' CYLINDER, PISTON AND CRANKSHAFT eS NOTE ON REMOVAL AND REASSEMBLY + Before servicing, clean the power unit. = Note the piston and connecting rod for cylinder #1 and #2, their should be reset in the originally. + Remove connecting rod, its cap should be kept as a set, do not mix. Extent of removal: @ Thermostat removal @ Stator assembly removal @ Piston removal @ Cylinder body disassembly Extent of removal | Order Part name Ory Remarks b 1 | Thermostat cover 1 2 | Thermostat 1 $ | 3 | Nut 1 4 | Flywheel magneto 1 | Refer to "REMOVAL POINTS’, 1 | 5 _| Stator assembly 1 6 | Stator bracket 1 7 | Timing bett 1_| Refer to “REMOVAL POINTS", 8 | Bolt 10 9 | Crankcase 1 10_| Bott 4 41 | Connecting cap 2 12. | Crankshaft 1 13 | Drive gear 1 | Refer to "REMOVAL POINTS", 14. | Circlip 4 15_| Piston pin 2 16 | Piston 2 17 | Exhaust cover (Outer) 1 18 | Exhaust cover (Inner) 1 [19 | oylinder body i REMOVAL POINTS FLYWHEEL MAGNETO 1. Remove: Nut © FZ Flywheel holder: YB-6139 / 90890-06522 2, Remove: + Flywheel magneto LF Flywheel puller: YB-6117 / 90890-06521 87|powr CYLINDER, PISTON AND CRANKSHAFT a TIMING BELT 1, Remove: + Timing belt © Nove: Remove the timing belt at the driven gear side. DRIVE GEAR 1, Remove: * Lock nut + Drive gear ® ‘Shaft holder: \F 1 90890-06069 NOTE: Before removing the lock nut, straighten the lock washer tab. INSPECTION AND REPAIR FLYWHEEL MAGNETO. 1. Inspect: + Flywheel teeth © Wear/Damage — Replace. DRIVE GEAR 1. Inspect: + Drive gear Wear/Damage —> Replace. 58POWR S| CYLINDER, PISTON AND CRANKSHAFT <>) TIMING BELT 1. Inspect: ing belt Stretch/Wear/Damage —- Replace. THERMOSTAT 1. Inspect: + Thermostat Stick/Damage —- Replace. 2, Measure: + Valve opening temperature + Valve lift Out of specification —> Replace. x Water temperature | Valve lift Below 58~62°C aseiaaey 0mm (0 in) Above 70C (158) | O19 ia) Measurement steps: + Suspend thermostat in a vessel Place reliable thermometer in a water. + Heat water slowly. + Observe thermometer, while stirring water continually. CYLINDER 1. Inspect: + Water jacket Mineral deposits/Corrosion —> Clean. + Oylinder inner surface Score marks —- Repair or replace. Use #600 ~ 800 grit wet sandpaper. 59POWR S| CYLINDER, PISTON AND CRANKSHAFT 2, Measure: + Oylinder bore “D* Use cylinder gauge. Out of specification + Rebore or Replace. NOTE: ———— Measure the oylinder bore "D” in parallel. Then, find the average of the measurement. A Standard Wear limit] PrandPs [ Cylinder [59.00 ~ 59.02 mm [59.1 mm bore D: | (2.323 ~ 2.324 in) | (2.326 in) $ Ds and De ‘Cylinder = 0.08 mm Ds and Oy — taper T: (0.003 in) — D = Maximum Dia (D, ~ De) aC T = (Maximum D, or D;) — (Minimum Ds or De) + Piston wall Wear/Scratch/Damage —> Replace. 2. Measure: Piston diameter Use a micrometer. Out of specification —- Replace. AA Distance @] Piston di [Standard| 10mm |58.950 ~ 58.965 mm| (0.39 in)_|(2.3209 ~ 2.3215 in) Over 1 59.25 mm (2.333 in) size 2 59.50 mm (2.343 in) NOTE: Measure specific distance @ from the bottom edge. 510POWR CYLINDER, PISTON AND CRANKSHAFT PISTON CLEARANCE. 1. Calculate: + Piston clearance Out of specification —- Replace piston and piston ring and/or cylinder. |_[riston DIAMETER PISTON CLEARANCE |~| _[ovunoer BORE Piston clearanct 0.035 ~ 0.065 mm (0.0014 ~ 0.0026 in) PISTON PIN 1. Inspect: Piston pin ‘Signs of heat discoloration —- Replace. 2. Measure: + Piston pin diameter Use a micrometer ®. Out of specification + Replace. Piston pin diameter: 13.996 ~ 14.000 mm (0.5510 ~ 0.5512 in) A 3. Check: + Free play (When the piston pin is into small end of connecting rod.) There should be no noticeable play. Free play exists —- Replace the pin and/or ‘connecting rod as required. a1POWR CYLINDER, PISTON AND CRANKSHAFT ej 4, Check: + Free play (When the piston pin is in place of the piston.) There should be no noticeable play. Free play exists —- Replace the pin and/or piston, PISTON RING 1, Measure: + Side clearance Using a feeler gauge @. Out of specification — Replace piston and/or ring. AX Side clearance: Top | 0.04 ~ 0.08 mm (0.002 ~ 0.003 in) ‘and | 0.03 ~ 0.07 mm (0.001 ~ 0.003 in) 2, Measure: +End gap Using a feeler gauge. Out of specification — Replace. a End gap: Top | 0.15 ~ 0.30 mm (0.006 ~ 0.012 in) 2nd | 0.15 ~ 0.30 mm (0.006 ~ 0.012 in} oi | 0.20 ~ 0.70 mm (0.008 ~ 0.028 in) NOTE: Install the piston ring into the ring with the piston crown. CRANKSHAFT 1. Measure: + Runout Use a V-blocks and dial gauge. Out of specification > Replace. Runout: 0.02 mm. (0.0008 in) 512POWR eS CYLINDER, PISTON AND CRANKSHAFT eS CRANKSHAFT MAIN BEARING CLEARANCE 1. Measure: + Oil clearance (Main journal) Out of specification —- Replace bearing. a ‘Main bearing clearance: 0.005 ~ 0.043 mm (0.0002 ~ 0.0017 in) ‘Measurement steps: CAUTION: Do not interchange the bearings. They must be installed in their original positions, or the correct oll clearance may not be obtained causing engine damage. * Clean the bearings, main journals and bearing portions of the crankcase and cylinder body. +Place the cylinder body on a bench in an upside down position. + Install haif of the bearings @) and crankshaft @ into the cylinder body @. NOTE: Align the projection @ of the bearing with the notch in the cylinder body. Put a piece of plastigauge onto the crankshaft journal surface. + Tighten the bolts in sequence and two steps of torque. Sy Bolt (Ma): ist: 15 Nm (1.5 mkg, 11 ftib) 2nd: 30 Nm (3.0 mrkg, 22 ftlb) Bolt (M6): ist: 6 Nm (0.6 mkg, 4.3 ft1b) 2nd: 12 Nm (1.2 mg, 8.7 ftlb) + Remove the bolts and the crankcase. *Measure the compressed plastigauge width on each main journal. COMBINATION OF CRANKCASE AND BEARING 1. Crankcase: Mark © Housing size A 33,082 ~ 33.040 mm (1.3005 ~ 1.3008 in) ) P 33,024 ~ 33.032 mm (1.3002 ~ 1.3008 in) A 33,016 ~ 33.024 mm (1.2998 ~ 1.3002 in) 2. Bearing: Indication © Bearing size Blue 1.508 ~ 1.512 mm (0.0594 ~ 0.0595 in) 1.504 ~ 1.508 mm cae (0.0592 ~ 0.0594 in) 1.500 ~ 1.504 mm mn (0.0591 ~ 0.0592 in) 3. Combination: Combine the crankcase and bearing by the following chart Grankcase mark | Bearing indication A Blue B Black c Brown 514POWR CYLINDER, PISTON AND CRANKSHAFT CONNECTING ROD OIL CLEARANCE 1. Measure: + Oil clearance Out of specification —- Replace connecting rod and cap as a set. x <>) Connecting rod oil clearance 0.021 ~ 0.045 mm (0.0008 ~ 0.0018 in) 515 Measurement steps: CAUTION; — Assemble the connecting rod and the cap referring the marking. + Do not assemble connecting rod and the cap with #1 and #2 together + Clean the bearing portions of the connecting rod. + Install the connecting rod to the crankshaft. +Put a piece of plastigauge onto the crank pin. + Install the connecting rod cap. NOTE: + Make sure that the “6G803” marks on the connecting rods face toward flywheel side of the crankshaft + Do not turn the connecting rod or crankshaft until clearance measurement has been completed. * Tighten the bolts in sequence in two steps of torque. iM 1st: 6 Nm (0.6 mkg, 4.3 ftlb) 2nd: 12 Nm (1.2 mrkg, 8.7 ft1b) + Remove the bolts and the connecting rod cap. *Measure the compressed plastigauge width on each crank pin Bolt (M8):CYLINDER, PISTON AND CRANKSHAFT ASSEMBLY AND INSTALLATION PISTON AND CONNECTING ROD 1. Install: + Expander ring © +Side ring @ 2. Install: *Piston ring (2nd) ® + Piston ring (top) @ Nove: + Align the piston ring gap with the pin of the piston. * Oil the pistons and rings liberally. 3. Install: +Piston ® +Connesting rod @ ton pin @ *Circlip @ NoTe:; +Mold mark @ faces in the same direction as the "UP* mark on the piston. + Always use a new circlip. +Oil the pistons, piston pins and connecting rods liberally. ‘CYLINDER AND CRANKCASE 1. Install: +Piston assembly * Cylinder body @ ve CAUTION: The piston should be installed with the “UP” mark on the piston crown facing toward the flywheel side. Piston slider: ‘YB-34454 / 90890-06529 516POWR CYLINDER, PISTON AND CRANKSHAFT > ry Note, 78 Position the ring end gaps before insert the fon. *Align the piston ring gap (top and 2nd) with the pin of the piston. @Side rail end gap ‘®Expander ring end gap ©Piston ring (2nd) end gap @Piston ring (top) end gap 2. Install: + Crankshaft main bearing @ NOTE: Align the projection of the bearings with the Notch in the cylinder body and crankcase. 3. Install: + Thrust plate D + Crankshaft @) NOTE: ——————— + Install the thrust plates so that the oil groove side is on the crank side. + When installing the crankshaft on the cylinder body, be sure to fit the thrust plate tab in the cut of the cylinder body. 4. Install: + Connecting cap @ + Bolt @ CAUTION: + Assembly the connecting rod and its cap referring the marking. + Do not assemble connecting rod and cap with #1 and #2 togeth 817 NOTE: Oil the connecting cap and crank pin liberally. Bolt: Ast: 6Nm (0.6 m-kg, 4.3 ft-Ib) 2nd: 13 Nm (1.3 m-kg, 9.4 ft-lb)powr| @y CYLINDER, PISTON AND CRANKSHAFT 5. Install: + Dowel pin ® + Oil seal (upper) @ + Oil seal (lower) @ NOTE: Install the oil seal with its manufacture’s marks or numbers facing outward. 6. Apply: + Gasket maker Onto the crankcase. NOTE: + Clean the contacting surface of the crankcase and cylinder body before applying the Gasket maker. + Gasket maker should be 89 applied that it does not overflow the contacting surface. 7. Install: +Crankcase D = Bolt (Ma) @ = Bolt (M6) @ NOTE: Tighten the bolts in sequence in two steps of torque. Ny Bolt: M8 1st : 15 Nm (1.5 mkg, 11 fib) 2nd: 30 Nm (3.0 m-kg, 22 ftlb) M6 1st: 6 Nm (0.6 mkg, 4.3 ftlb) 2nd: 12 Nm (1.2 mkg, 8.7 ft1b) EXHAUST COVER 1. Install: + Gasket © + Exhaust cover (inner) @ + Exhaust cover (outer) @ Bolt @ NOTE: Tighten the bolts in sequence in two steps of torque. 518CYLINDER, PISTON AND CRANKSHAFT e TIMING BELT 1. Install: + Washer + Woodruff key @ + Drive gear @ +Washer @ NOTE: + The projections on the drive gear should fit into the holes in the washers. *"TOP" mark side should face upward. 2. Install: + Lock washer @) +Nut Nove: + Insert the projection of the lock washer to be matched with the "TOP" mark. + After tightening the nut, bend the lock washer ‘over the nut. ea Shaft holder / 90890-06069 Ng Nut: 23 Nm (2.3 mkg, 17 ftlb) 3. Align: + Drive gear mark + Cylinder body mark © NOTE: Turn the crankshaft clockwise. 519POWR' eS CYLINDER, PISTON AND CRANKSHAFT S 4, Align: + Drive gear mark @ + Cylinder head mark @ NOTE: Tur the camshaft clockwise. 5. Install: yaaa + Timing belt ® CAUTION: «Protect the belt from water and oil. + Do not use an iron lever when installing the belt. + Use care not to scratch the belt. NOT! ———— +Be sure that the "YAMAHA" mark is not inverted, + Place the timing belt around the drive gear and then around the driven gear. + When placing the timing belt around the driven gear, lock both drive and driven gears so that they do not turn. OIL PRESSURE SWITCH 4. Install: + Oil pressure switch © Nx Oil pressure switch: 9 Nm (0.9 m-kg, 6.5 ft-Ib) 2. Install: + Switch lead @ + Screw @ + Cover @ NOTE: Route the switch lead over the recess in the cylinder body. Ng ‘Screw: 2.Nm (0.2 mkg, 1.4 ft'lb) 520POWR CYLINDER, PISTON AND CRANKSHAFT > THERMOSTAT 1. Install: + Thermostat D Gasket @ + Thermostat cover @) + Bolt @ + By-pass hose §) NOTE: Always use a new gasket. STARTER MOTOR 1. Install: Bracket ® + Bolt @ x Install: + Battery lead © + Nut @ +Starter motor @ *Bolt @ Ng Nut: 4.Nm (0.4 mkg, 2.9 ftlb) 521 3. Install: + Relay bracket + Starter relay assembly Bolt @ + Battery lead @ +Washer @ =Nut © Nove; + Secure, together with the starter relay ground lead @. + Connect the battery lead to both of the starter motor and starter relay. Na Nut: 4 Nm (0.4 mrkg, 2.9 ftlb)POWR CYLINDER, PISTON AND CRANKSHAFT FLYWHEEL MAGNETO 1. Install: + Dowel pin @ + Stator bracket @ +Screw @ + Stator assembly @ Bolt © + Woodruff key 6) 2. Install: + Flywheel magneto @ Washer @) + Nut @ YF Flywheel holder: l YB-6139 / 90890-06522 Ng ‘Nut: 100 Nm (10 mkg, 72 ft-lb) 522PowR| S CYLINDER HEAD, VALVE AND CAMSHAFT eS CYLINDER HEAD, VALVE AND CAMSHAFT PREPARATION FOR REMOVAL * Remove the power unit. Remove the following parts: CDI unit + Rectifier regulator «Ignition coil + Flywheel magneto * Stator assembly + Timing belt 7B] 2 Nim (02 ekg, 14 Feb) TSA B | @Nm (8 mwkg, 58 fb) Ba wl LES c 13 Nm (1.3 mrkg, 9.4 ftib) 8 y D 18 Nm (1.8 mkg, 13 ftib) -_ E Ast: 15 Nm (1.5 mkg, 11 ftlb) 2nd: 30 Nm (3.0 m-kg, 22 ft-lb) 523POWR CYLINDER HEAD, VALVE AND CAMSHAFT NOTE ON REMOVAL AND REASSEMBLY + Before servicing, clean the power unit. + Remove any gasket adhered to the contacting surface, + Take care not to scratch the contacting surfaces when removing the oylinder and cylinder head. + Forreassembly, the removed parts should be cleaned with solvent, and apply gear oiltothe sliding surfaces. 16 | Valve cotter 17 | Valve (intake) 18 | Spring retainer 19 | Valve (exhaust) Refer to "REMOVAL POINTS" Extent of removal: @ Intake manifold removal @ Cylinder head removal @ Oil pump assembly removal @ Valve disassembly Extent of removal | Order Part name ay Remarks o 1 1 | Bolt 3 2 | Intake manifold 1 3 | Bott 4 4 | Cylinder head cover 1 5_| Bott 8 _ 6 | Cylinder head 1 _ | Refer to “REMOVAL POINTS" | 7 | Bot 3 8 | Oil pump assembly 1 9. | Adjust screw 4) | Loosen the screw. 10_| Valve iifter 2 | | Refer to “REMOVAL POINTS’. 11 | Rocker shaft 2 12 | Rocker arm 4 13 | Bolt 1 14 | Driven gear 1 _| Refer to "REMOVAL POINTS". 15_| Camshaft 1 4 2 2 2 REMOVAL POINTS CYLINDER HEAD 1, Remove: + Cylinder head D NOTE: *To remove the cylinder head, insert a bar between the cylinder head and cylinder body, and then separate it. ‘Do not to scratch the gasket contact surfaces by the screw driver. ROCKER SHAFT 1, Loosen: Lock nut + Adjust screw @ Wy Valve adjuster: YB-8035 / 90890-01311 524POWR CYLINDER HEAD, VALVE AND CAMSHAFT >) 2, Remove: Rocker shatt © NOTE: Use M10 bolt to extract the rocker shaft. DRIVEN GEAR 1. Remove: +Bolt © *Driven gear @ Z| Flywheel holder: YB-6139 / 90890-06522 VALVE 1, Remove: + Valve cotter © +Valve @ iF Valve spring compressor: ‘YM-1253 / 90890-04019 Nott es Hold down the valve spring and remove the valve cotter. 2. Remove: + Valve lifter + Spring retainer D +Valve @ A Valve spring compressor: YM-1253 / 90890-04019 NOTE: Hold down the valve spring, remove the valve lifter and slide out the retainer. 525POWR| eS CYLINDER HEAD, VALVE AND CAMSHAFT ce} —l { —) INSPECTION AND REPAIR OIL SEPARATOR 1. Measure: + Reed valve warpage @ Out of specification —- Replace. Reed valve warpage limit: 0.2 mm (0.008 in) lL PUMP 4. Measure: + Clearance @ (between outer rotor @ and pump housing i) +Clearance © (between inner rotor @ and outer rotor D) + Clearance © (between out rotor @ and pump housing @) Use a feeler gauge. Out of specification —- Replace oil pump assembly. Clearance: 0.06 ~ 0.11 mm (0.0024 ~ 0.0043 in) 5.26 0.02 ~ 0.15 mm (0.0008 ~ 0.0059 in) (0.05 ~ 0.07 mm (0.0020 ~ 0.0028 in) olele Pa ROCKER SHAFT AND ROCKER ARM 1, Measure: + Rocker shaft diameter Out of specification + Replace. Rocker shaft diameter: 12.94 ~ 12.95 mm (0.509 ~ 0.510 in)Powr| @y CYLINDER HEAD, VALVE AND CAMSHAFT > 2. Inspect: Rocker arm @ Scratch/Damage ~ Replace. + Adjust screw @) Wear/Damage —> Replace. 3. Check: + Free play (When the rocker shaft is in place of the rocker arm.) There should be no noticeable play. Free play exists + Replace the rocker shaft and/or rocker arm, VALVE LIFTER 1. Inspect: Valve lifter Scratch/Damage — Replace. CAMSHAFT 1. Inspect: +Cam lobes Pitting/Scratch/Blue dis coloration — Replace. 2. Measure: +=Cam lobe length @ +Cam lobe length © Out of specification —- Replace. 57POWR CYLINDER HEAD, VALVE AND CAMSHAFT eS Cam lobe length: nm 24.541 ~ 24.641 mm (0.966 ~ 0.970 in) oO = 24.578 ~ 24.678 mm (0.968 ~ 0.972 in) y 20.137 ~ 20.237 mm (0.793 ~ 0.797 in) oI ex 20.178 ~ 20.278 mm (0.794 ~ 0.798 in) 528 CYLINDER HEAD 1. Inspect: + Water jacket Mineral deposits/Corrosion —> Clean. + Combustion chamber Carbon deposits —> Clean. Use a round scraper. 2, Measure: + Cylinder head warpage Use a straightedge and thickness gauge. ut of specification — Replace the valve Warpage limit: 0.1 mm (0.004 in) Resurfacement steps: «Place a 400 ~ 600 grit wet sandpaper on the surface plate. +Resurface the head using a figure-eight sanding pattern. NOTE: Rotate the head several times to avoid removing too much material from one side. 3. Inspect: *Valve guide © Wear/Damage —> Replace.CYLINDER HEAD, VALVE AND CAMSHAFT > 4, Measure: + Valve guide bore @ Use a bore gauge ®. Out of specification + Replace the valve guide. o AA Valve guide bore: IN 5.500 ~ 5.512 mm EX (0.2165 ~ 0.2170 in) Replacement steps: NOTE: Heat the cylinder head in an oven to 200°C (892°F) to ease guide removal and installation and to maintain correct interference fit. + Remove the valve guide using the valve guide remover. Valve guide remover: YM-1122 / 90890-06801 + Install the circlip and valve guide (new) using the valve guide installer and valve guide remover. Valve guide installer: ‘YB-6308 / 90890-06802 “After installing the valve guide, bore the valve guide using the valve guide reamer to obtain proper stem-to-guide clearance. Valve guide reamer: YM-1196 / 90890-06804 5. Eliminate: + Carbon deposit from valve face and valve seat. 6. Inspect: + Valve seat Wear/Pitting —- Reface the valve seat.CYLINDER HEAD, VALVE AND CAMSHAFT > 7. Measure: + Valve seat width @ Out of specification + Resurtace. a4 Valve seat width: IN 0.6 ~ 0.8 mm EX (0.024 ~ 0.031 in) Measurement steps: + Apply the Mechanic's bluing dye @ to the valve face. + Install the valve into the cylinder head. + Press the valve through the valve guide onto the valve seat to make a clear pattern. «Measure the valve seat width, Wherever the valve seat and valve face made contact, bluing will have been removed. 8. Reface: + Valve seat Use a 30°, 45° and 85° valve seat cutter. iZ] Valve seat cutter set: ‘YM-91043-C / 90890-06803 CAUTION: — When twisting cutter, keep an even downward pressure (4 ~ 5 kg) to prevent chatter marks. 5:30POWR CYLINDER HEAD, VALVE AND CAMSHAFT QS Cut sections as follows Section Cutter A 85° - 5 7 IX ae c 30° Refacing steps: [A] Valve seat is centered on valve face but it is too wide. Valve seat cutter set| Desired result Use | 85° cutter | To reduce valve lightly [30° cutter | Seat width. [Bl Vaive seat is in middle of the valve face but itis too narrow. Valve seat cutter set| Desired result To achieve a Use | 45° cutter | uniform vaive seat width, [CJ Vaive seat is too narrow and it is near valve margin. Valve seat cutter set| Desired result 85° cutter, | To center the seat Use first | and to achieve its 45° cutter | width. [D Vaive seat is too narrow and it is located near the bottom edge of the valve face. Valve seat cutter set] Desired result 30° cutter, | To center the seat Use first | and to increase its 45° cutter | width. 631powr| Gy CYLINDER HEAD, VALVE AND CAMSHAFT ce} 9. Lap: +Valve face *Valve seat NOTE: After refacing the valve seat or replacing the valve an¢ valve guide, the valve seat and valve face should be lapped. Lapping steps: + Apply a coarse lapping compound to the valve face. CAUTION: Be sure no compound enters the gap between the valve stem and guide. “Apply a molybdenum disulfide oil to the valve stem. + Install the valve into the cylinder head. + Turn the valve until the valve face and valve seat are evenly polished, then clean off all compound. NOTE: To obtain the best lapping results, lightly tap the valve seat while rotating the valve back and forth between your hands. “Apply the fine lapping compound to the valve face and repeat the above steps. NOTE: Be sure to clean off all compound from the valve face and valve seat after every lapping ‘operation. 532 = Apply the Mechanic's bluing dye to the valve face. + Install the valve into the cylinder head. + Press the valve through the valve guide and ‘onto the valve seat to mark a clear pattern.POWR) CYLINDER HEAD, VALVE AND CAMSHAFT > Ht the + Measure the valve seat width agai valve seat width is out of specification, reface and lap the valve seat. VALVE 1. Inspect: *Valve face Carbon deposits —- Clean. Pitting/Wear —> Grind the face. + Valve stem end Mushroom shape or diameter larger than rest of stem —- Replace. 2. Measure: + Margin thickness @ Out of specification + Replace. CTD a4 Margin thickness: IN 0.5 ~ 0.9 mm EX (0.020 ~ 0.035 in) Ns 3, Measure: ® + Valve stem diameter 1 Out of specification ~ Replace iL / AA Valve stem diameter: IN 5.475 ~ 5.490 (0.2156 ~ 0.2161 in) Ex 5.460 ~ 5.475 mm (0.2150 ~0.2156 in) 4, Measure: * Valve stem runout Out of specification - Replace. a Stem runout limit IN 0.016 mm Ex (0.0006 in) 533POWR CYLINDER HEAD, VALVE AND CAMSHAFT > NOTE: + Always replace the guide if the valve is replaced. + Always replace the oil seal if the valve is remove d. VALVE SPRING 1. Measure: + Compressed forth Out of specification + Replace. Compressed forth: 534 IN | Set length @ a ° to in EX. | 24.4 mm (0.96 in) | {35 — oa0 In) 2, Measure: + Spring tit Out of specification + Replace. AA Tilt limit: IN ex 1.1 mm (0.43 in)CYLINDER HEAD, VALVE AND CAMSHAFT ce) ® ASSEMBLY AND INSTALLATION \ OIL PUMP ASSEMBLY 1. Install: «Pump housing ® + Outer rotor @ +Inner rotor @) Shaft @ +Oxing © +Pump cover © + Screw NOTE: * Align the shaft with the hole in the inner rotor shaft and insert. Oil the rotors liberally before installing the pump cover. CYLINDER HEAD 1. Install: Oil seal © +Screw @ Anode @ + O-ring @ Bolt © NOTE: Install the oil seal with its manufacture’s marks ‘or numbers facing outward. Na Bolt: 18 Nm (1.8 mkg, 13 ftb) 2. Apply: + Engine oll Onto valve and oil seal @ rn NOTE: 4 Always use a new oil seal. 535POWR CYLINDER HEAD, VALVE AND CAMSHAFT Sp 2. Install: + Valve (intake) @ +Oil seal @ + Spring seat @ *Valve spring © + Spring retainer ©) *Vaive cotter © SF Valve spring compressor: ‘YM-1253 / 90890-04019 NOTE: +Hold down the valve spring and install the valve cotter. + Secure the valve cotter onto the valve stem by tapping it lightly with a piece of wood. 4. Install: *Valve (exhaust) D + Oil seal @ + Spring seat @ +Valve spring @ + Spring retainer ©) ‘ +Valve lifter © YM-1253 / 90890-04019 SA i Valve spring compressor: NOTE: \ + Hold down the valve spring, install the spring retainer and slide in the retainer. YX ® + Secure the valve lifter onto the valve stem by yo \ by ® tapping it lightly with a piece of wood. @ 5:36CYLINDER HEAD, VALVE AND CAMSHAFT ce 5. Install: + Camshaft ® + Washer @) + Woodrutt key @ * Driven gear @) + Washer ©) =Bolt ® Vad Ss Flywheel holder: YB-6139 / 90890-06522 Bolt: 13 Nm (1.3 mkg, 9.4 fb) 6. Apply: + Engine oil ‘Onto rocker shaft and rocker arm. 7. Install: + Rocker shaft (exhaust) ® +Collar @ + Rocker arm @ + Compression spring (short) @ +Collar ©) Rocker arm © Compression spring (short) @ NOTE: 537 Install the rocker shaft so that the internal thread side is on your side. 8. Install: + Rocker shaft (intake) ® + Compression spring (long) @ + Rocker arm @) +Collar @ + Compression spring (short) © + Rocker arm ©CYLINDER HEAD, VALVE AND CAMSHAFT eS» 638 9. Install: + O-ring D + Oil pump assembly @ + Bolt @ Nove: Align the recess in the oil pump shaft with the ‘camshatt projection. 10. Install: + O-ring @ = Dowel rin @ Gasket @ + Cylinder head assembly @ Bolt ® Ng Bolt: MBtst : 15 Nm (1.5 mrkg, 11 ftib) 2nd: 30 Nm (3.0 mkg, 22 ftb) CAUTION; — When installing the cylinder head on the cylinder body, set the piston at bottom dead center (BDC} otherwise, the piston may butt against valves, thus damaging them. NOTE: Apply the engine oil to the thread of each oylinder head fixing bolt and seat surface. + Tighten the bolts in sequence and two steps of torque. 11. Install: + Timing belt Refer to page 5-20. 12. Adjust: + Valve clearance Refer to page 3-18.CYLINDER HEAD, VALVE AND CAMSHAFT ce CYLINDER HEAD COVER 4. Install: +Seal @ + Cylinder head cover @ +Bolt @ + O-ring @ + Oil filler cap © INTAKE MANIFOLD 4. Install: + Stud bolt © +Gasket @ + Intake manifold @ + Bracket ® +Clamp © “Bolt © «Clamp @ + Washer ® + Nut @ OIL SEPARATOR 1. Install: + Reed valve D + Washer @ ao | os Screw: Nstse Na] 2.Nm (0.2 mrkg, 1.4 fb) 2. Install: + Oil separator body © + Gasket @ + Breather @ + Screw @ + Gasket © *Cover © + Screw @ 539POWR CYLINDER HEAD, VALVE AND CAMSHAFT 5 NOTE: Always use a new gasket. ‘Screw: 2.Nm (0.2 mkg, 1.4 fttb) 3. Install: + Oil separator + Screw @ + Hose (long) @ + Hose (short) @ + Hose (breather) ©)POWR RECOIL STARTER RECOIL STARTER PREPARATION FOR REMOVAL * Remove the power unit. * Remove the flywheel magneto. A WARNING + Wear a proper protect your +Use care, the spir injure a person. + When removing the shi 80 that the spiral spring gogle and gloves for id hands. Jumps out and may irum, use care not jump out. 541POWR S| RECOIL STARTER Extent of removal: @ Recoil starter removal @ Recoil starter disassembly @ Starter rope removal Extent of removal [Order Part name oy Remarks o} 1 | Bot 3 2. | Recoil starter assembly 1 3 | Bolt 2 4 | Guide plate 1 5 _| Bott 1_| Loosen the lock nut 6 | Pin 1 7 1 a |e topper arm 10_| Bott 3 11 | Cover 1 12 | Cotter pin 1 13. | Drum stopper 1 14 | Bott 1 18_| Roller 1 16 | Sheave drum 1 Fi 7 19 | Stans rope 1 } | Reter to "REMOVAL POINTS 18_| Spiral spring 1. | Refer to “REMOVAL POINTS"! REMOVAL POINTS STARTER ROPE 1. Remove: +Sheave drum D + Starter rope @ NOTE: Insert a slotted-head screwdriver into the hole in the sheave drum, and remove the spiral spring from the sheave drum by pushing the spring.POWR S| RECOIL STARTER 2S SPIRAL SPRING 1. Remove: + Spiral spring © NOTE: Hold the starter housing @ with the spiral spring facing downward. Insert a standard-head screwdriver into the hole in the sheave drum shaft, and push the sprial spring out. INSPECTION STARTER ROPE 1. Inspect: + Starter rope Damage — Replace. SPIRAL SPRING 1. Inspect: + Sprial spring Wear/Damage —~ Replace. SHEAVE DRUM AND STARTER HOUSING 1. Inspect: + Sheave drum D + Starter housing @ Damage —» Replace. PINION 1. Inspect: + Pinion Damage —- Replace. 543POWR eS | RECOIL STARTER S ASSEMBLY AND INSTALLATION 1. Install: + Starter housing © + Thrust washer @) * Spiral spring @ NOTE: 1. When installing the new spiral spring, do not ‘cut the wire holding the spring. After installing, cut the wire. 2, When reusing the spiral spring, set the lead- ing end first in the housing and then fit one turn each time. Use special care. The spring can easily come off. The spiral spring may jump out so use ‘special care. 2. Install: + Starter rope © *Sheave drum @ NOTE: + Make a knot on one end. +Pass the rope through the hole in the sheave drum and wind it 5.5 turns around the drum. +Place the rope in the recess on the drum. 3. Install: * Bushing ® +Roller (2) Washer @) + Spring washer @ +Bolt © NOTE: After installing, route the starter rope between the starter roller and starter housing. 4. Install: + Starter housing © NOTE: ——____ Fit the spiral spring hook into the sheave drum groove. 544POWR RECOIL STARTER 5-45 5. Install +Drum stopper + Stopper spring @ Collar @ Washer @ +Cotter pin © Install + Cover D + Spring washer @) + Bolt @ . Install: +Arm spring ® + Stopper arm @ + Washer @ + Spring washer @ +Bott © CAUTION; — Firmly hold the rope or the rope will be pulled in. Note: + Hook the spring onto the starter housing and stopper arm. + Align the arrow marks on the collar and stopper arm, + After assembling, wind the rope 4 turns clockwise around the sheave drum to contract the spring. +While holding the rope firmly, tie the rope temporarily to the starter roller.POwR' eS RECOIL STARTER 546 8. Install: + Washer @ Bus ® +Pinion @ + Friction spring @ +Pin® + Washer © Bolt @ + Lock nut © CAUTION: Do not open the spring end gap to fit it, or the gap will become large, thus making the spring unusable. It should be fit in the same manner as a piston ring. 9. Install: + Protector © +Damper @) + Guide plate @ + Spring washer @ +Bolt © NOTE: Put the protector into the loop of the friction spring. 10. Install: + Recoil starter assembly +Bolt @ 11. Install + Start in-gear protection wire Refer to page 5-4.lowr € CHAPTER 6 LOWER UNIT LOWER UNIT 6-1 PREPARATION FOR REMOVAL (T9.9/F9.9A) NOTE ON REMOVAL AND REASSEMBLY ... PREPARATION FOR REMOVAL (F9.9/F9.9B) NOTE ON REMOVAL AND REASSEMBLY REMOVAL POINTS .. Shift shaft .. Pinion gear Needle bearing .... Bearing outer 1462 «nen Reverse gear complete .... Forward gear complete (F9.9/F9.9B). INSPECTION AND REPAIR Lower case .. Bearing housing Water pump housing .. Impeller . Shift shaft Gear Bearing .. Drive shaft Propeller shatt .. Dog clutch Sleeve Propeller/anode ... ASSEMBLY AND INSTALLATION Forward gear Propeller shaft .. Reverse gear Oil seal housing .. Lower case ee . 612 Shim selection (For USA and CANADA), . 6:15 Shim selection (Except for USA and CANADA) 617 Backlash measurement Water pump Lower unit . PropellerLOWR € LOWER UNIT LOWER UNIT PREPARATION FOR REMOVAL (T9.9/F9.9A) * Drain the gear oil. A] 26 Nm (2.6 m-kg, 19 ft-Ib) B | 131Nm (1.3 m-kg, 9.4 ft-Ib)Lowr € LOWER UNIT NOTE ON REMOVAL AND REASSEMBLY Tilt up the engine alittle marks easier + Remove any gasket adhered to the contacting surface. draining. +The shim pack will be re-use therefore use care not to damage when removing. + For reassembly, the removed parts should be cleaned with solvent. Extent of removal: @ Lower unit removal @ Lower unit disassembly @ Impeller remove Extent of removal Order Part name Qty Remarks Cotter pin Nut Propeller Spacer Nut Bolt Lower unit Bolt 10 _ | Water pump housing 1 2 3 4 5 _| Lock nut 6 7 8 9 11 | Impelier 12 | Woodruff key 13 | Gasket 14. | Outer plate 15 | Screw 16 | Shift shaft Refer to "REMOVAL POINTS". 17 | Bolt 18 | Reverse gear complete 19 | Propeller snaft complete 20_| Nut Refer to “REMOVAL POINTS” Refer to “REMOVAL POINTS". 21 | Pinion gear 22 | Thrust bearing 23. | Pinion gear shim 24 | Drive shaft 25 _| Forward gear complete 26 | Oilseal housing 27 | Sleeve 28 | Needle beering Refer to “REMOVAL POINTS". 29. | Bearing outer race Refer to "REMOVAL POINTS”. 30__| Reverse gear 31 _| Reverse gear shim 3 | Saget } | ptr nenoval pons: 33 | Needle bearing 34 | Cross pin ring 35 _| Cross pin 36 | Dog clutch 37 | Taper roller bearing 38 | Forward gear shim 39 _| Foeward gear testes atesestestes | eestesteaten | estes | Msteateay pti | teen | at | 62LOWR| € LOWER UNIT QS PREPARATION FOR REMOVAL (F9.9/F9.9B) * Drain the gear oil.+ Remove any gasket adhered to the contacting surface. LOWER UNIT NOTE ON REMOVAL AND REASSEMBLY Tilt up the engine alittle marks easier oil draining, +The shim pack will be re-use therefore use care not to damage when removing. + For reassembly, the removed parts should be cleaned with solvent. Extent of removal: @ Lower unit removal @ Lower unit disassembly @ Impelier remove Extent of removal_| Order Part name ay Romarks 1 | Cotter pin 1 2 | Nut 1 3 | Propeller 1 4 | Spacer 1 5 _| Lock nut 1 6 [Na 1 7 | Bot 4 8 | Lower unit 1 9 | Bot 4 10 _| Weter pump housing 1 11 | Impeller 1 12 | Woodrut key 1 13. | Gasket 2 14 | Outer plate 1 15__| Screw 1 16 | Shit shaft 1 | Refer to “REMOVAL POINTS” 17 | Bot 2 18 | Reverse gear complete 1 _ | Refer to "REMOVAL POINTS”. 19 | Propeller shaft complete 1 20, | Nut 1__| Refer to “REMOVAL POINTS". 21 | Pinion gear 7 22 | Thwust bearing 1 23 | Pinion gear shim 1 24 | Drive shaft 1 25 _| Forward gear complete 1 26 | Oilseal housing 1 27 | Sleeve 1 28 | Needle bearing 1 _ | Reter to "REMOVAL POINTS" 29. | Bearing outer race 1 _ | Refer to "REMOVAL POINTS” 30__| Forward gear shim 1 31_| Reverse gear 1 32. | Reverse gear shim 1 33 | Ballbearing 4 “ 7 eat Novas tee 1} | Refer to “REMOVAL POINTS" 35 _| Cress pin ring 1 36 | Cress pin 1 37 | Dog clutch 1 38 | Taper roller bearing 1 39_| Foeward gear 1_| Refer to “REMOVAL POINTS". 64LOWR| € | LOWER UNIT REMOVAL POINTS SHIFT SHAFT 1. Remove: +Screw + Bracket @ + Shift shaft @ NOTE: Push the projections of the bracket evenly (as, ‘shown in the illustration) and pull the bracket up. PI ION GEAR 1. Remove: = Nut @ + Pinion gear @ YB-6078 Drive shaft holder YB-6228/90890-06515 7 Pinion nut holder: T9.9/F9.9A 4o F9.9/F9.98 65 NEEDLE BEARING 1, Remove: + Needle bearing iF Drive rod: YB-6229/90890-06602 Needle bearing attachment: T9.9/F9.9A: YB-6298/90890-06618 F9.9/F9.9B: YB-6230/90890-06617 BEARING OUTER RACE 1. Remove: + Bearing outer race + Forward gear shim (F9.9/F9.9B only) @) x ‘Slide hammer set Bearing puller: 90890-06535 Stopper guide sta 90890-06538 ... For USA and CANADA Except for USA and CANADA eee @eLown] | LOWER UNIT QS Stopper guide stai 90890-06538 For USA and CANADA Except for USA and CANADA REVERSE GEAR COMPLETE 1, Remove: + Ball bearing © FZ Slide hammer set: ‘YB-6096 .. @ Stopper guide plate: 90890-06501 . ®@ Bearing puller: 90890-06535 ~® ~® 2. Remove: *Oil seal © + Needle bearing @ FZ Drive rod: YB-6071/90890-06604 Needle bearing attachment: YB-6081/90890-06616 FORWARD GEAR COMPLETE (F9.9/F9.9B) 4. Remove: + Taper roller bearing © Forward gear @ Bearing separator: YB-6219/90890-06534ILOWR| LOWER UNIT INSPECTION AND REPAIR LOWER CASE 1. Clean: + Gear case Use a soft brush and solvent. 2. Inspect: + Water passage Mineral deposits/Corrosion —- Clean. 3. Inspect: + Lower case Crack/Damage —> Replace. BEARING HOUSING 1. Clean: + Bearing housing Use a soft brush and solvent. 2. Inspect: + Bearing housing Crack/Damage —> Replace. WATER PUMP HOUSING 1. Inspect: + Water pump housing Crack/Damage —> Replace. IMPELLER 1. Inspect: + Impeller Crack/Damage —» Replace. 67LOWER UNIT SHIFT SHAFT 1. Inspect: + Shift plunger Wear/Damage — Replace. 2. Inspect: Boot Break/Damage ~ Replace. GEAR 1. Inspect: +Teeth «Dogs Wear/Damage — Replace. BEARING 1. Inspect: + Bearing Pitting/Fumbling —- Replace. DRIVE SHAFT 1. Inspect: * Drive shaft Wear/Damage —> Replace. 68[Lowe € LOWER UNIT PROPELLER SHAFT 1. Inspect: + Propeller shaft Wear/Damage — Replace. DOG CLUTCH 1. Inspect: + Dog clutch ; Wear/Damage —> Replace. SLEEVE 1. Inspect: + Sleeve Oo) Wear/Damage —> Replace. PROPELLER/ANODE. Refer to page 3-9 ~ 3-10. 69LOWER UNIT eS T9.9/F9.9A ASSEMBLY AND INSTALLATION FORWARD GEAR 1. Install: (T9.9/F9.9A) + Forward gear shim @) + Taper roller bearing @ + Forward gear @) NOTE: The shim is installed for T9.9/F9.9A model only. F9.9/F9.9B 9.9/F9.9A eee 1. Install: (F9.9/F9.9B) + Taper roller bearing ® + Forward gear @) PROPELLER SHAFT 1. Install + Spring + Plunger @ + Dog clutch @ + Cross pin @ + Cross pin ring © NOTE: Install the clutch with “F” mark toward the forward gear side. REVERSE GEAR 1. Install: «Needle bearing D Va Drive rod: ‘YB-6071/90890-06604 Needle bearing attachment: YB-6081/90890-06616 F9.9/F9.9B { ~O Depth @: T9.9/F9.9A: 0 mm (0 in) F9.9/F9.9B: 0 mm (0 in) NOTE: Install the needle bearing with its manufacture’s marks or numbers toward the propeller side. 610ILOWR| € | LOWER UNIT eS 2. Install: + Oil seal © iA il seal installer: YB-6078 Drive rod: YB-6229 Depth @: 79.9/F9.9A: 4.5 ~ 5.0 mm (0.18 ~ 0.20in) F9.9/F9.9B: 2.5 ~ 3.0 mm (0.10 ~ 0.12in) 3. Install: * Ball bearing © # Bearing installer: ‘YB-6015/90890-06632 Drive rod: YB-6071/90890-06606 NOTI Install the bearing with its manufacture’s marks or numbers facing outward. 4. Install: “O-ring @ + Reverse gear shim @ + Reverse gear @) + O-ring @ OIL SEAL HOUSING 1. Install: + O-ring D KF Oil seal installer: enILOWR| LOWER UNIT i T9.9/F8.9A —O oO F9.9/F9.0B ao LOWER CASE 1. Install: (T9.9/F9.9A) + Bearing outer race @ KZ Bearing instal YB-6085/90890-06625 Drive rod: YB-6071/90890-06605 1. Install: (F9.9/F9.9B) + Forward gear shim @ “Bearing outer race @ Bearing installer: YB-6085/90890-06625 Drive rod: YB-6071/90890-06605 installed for F9.9/F9.9B model only. 2. Install: + Needle bearing © Drive rod: YB-6229 Needle bearing installer: YB-6231 Needle bearing attachment: 79.9: YB-6298 F9.9: YB-6230 Drive rod: ‘90890-06502 Bearing depth plate: 90890-06803 Needle bearing attachment: F9.9A: 90890-06818 F9.9B: 90890-06517 [A] For USA and CANADA Except for USA end CANADA ISS © © 68 © 8 AA Depth @ T9.9/F9.9A: 199.6 ~ 200.1 mm (7.86 ~ 7.88 in) F9.9/F9.9B: 182.2 ~ 182.7 mm (7.17 ~ 7.19 in) 612ILOWR) LOWER UNIT & 613 NOTE: ————— Install the bearing with its manufacture’s marks or numbers facing outward. 3. Install: + Dowel pin ® +Sleeve @ + Gasket @ *Oil seal housing @ NOTE: —————— Install the sleeve with projection side backward. 4. Install: + Forward gear complete 5. Install: * Drive shaft +Pinion gear shim @ Washer (thick) @ Bearing @ + Washer (thin) 6) +Pinion gear © + Nut @ Pinion nut holder: YB-6078 Drive shaft holder: ‘YB-6228/90890-06515 Nut: 26 Nm (2.6 m-kg, 19 ft-Ib)rc ILOWR' LOWER UNIT 614 6. Install: * Shift shaft © Bracket @ +Screw @ 7. Install: + Propeller shaft complete @ + Reverse gear complete @ +Bolt @ 8. Check: + Shift cam operation Unsmooth operation ~ Repair. NOTE: Check that the dog clutch shifts to “Forward”, “Neutro!" and “Reverse” correctly.Lown| € | LOWER UNIT SHIM SELECTION (For USA and CANADA) NOTE; When reassembling the lower unit with the original gear case and inner parts, shim selection is not required. + When replacing the gear case or inner parts, carry out the shim selection. 1. Measure: *Pinion gear clearance Out of specification —- Adjust. Clearance: 79.9: 0.45 ~ 0.55 mm F9.9: 1.15 ~ 1.25 mm A Measurement steps: “Install the drive shaft components and tighten the nut to the specified torque. 19.9 | — | + Attach the shimming tool into the gear case. Pinion height gauge: 7 9.9: YB-6299 F9.9: YB-34232 + Measure the clearance end determine the shim thickness. 79.9 Less than To be decreased by F929] [0.45 mm (0.50 ~ measurement) More than To be increased by 0.55 mm (measurement - 0.50) F9.9 Less than To be decreased by 4.45 mm (1.20 - measurement) More than! To be increased by 4.25 mm (measurement - 1.20) 615LOWR € LOWER UNIT Example: (F9.9/F9.9B) If measurement = 1.02 mm Decrease shim thickness by .20 — 1.02 18 mm Hf measurement = 1.32 mm Increase shim thickness by = 1.32 — 1.20 = 0.12 mm 3%] ‘avaiable shim thickness: 79.9: 0.10, 0.14, 0.18 and 0.50 mm F9.9: 0.10, 0.12, 0.15, 0.18, 0.30, 0.40 and 0.50 mm NoTe; + Forward and reverse shim selection will be done by "BACKLASH MEASUREMENT’ section. ince the smallest shim available is 0.10 mm, the measurementis between (T9.9) 0.45 and 0.55 mm or (F9.9) 1.15 and 1.25 mm do not change the shim. 616LOWR | LOWER UNIT SHIM SELECTION (Except for USA and CANADA) NOTE: — + When reassembling the lower unit with the original gear case and inner parts, shim selection is not required + When replacing the gear case or inner parts, ‘carry out the shim selection, 1. Adjust: + Pinion shim thickness Adjustment steps: ‘Measure the thicknesses (Mv3) of bearing and washer. Digital caliper: 90890-06704 *Use the following equation to calculate the pi- rion shim thickness (T3). AA F9.9A: T3 = 5.99 — Mv3 F9,9B: T3 = 6.05 — Mv3 ‘Available shim thickness: F9.9A: 0.10, 0.14, 0.18 and 0.50 mm F9.9B: 0.10, 0.12, 0.15, 0.18, 0.30, 0.40 and 0.50 mm 617LOWER UNIT 2. Adjust: * Forward gear shim thickness Adjustment steps: ‘+ Measure the dimension (Mv1). Shimming plate: 90890-06701 A Digital caliper: 90890-06704 *Use the following equation to calculate the pi- rion shim thickness (T1), A F9.9A: T1 = 16.50 — Mv1 F9.9B: T1 = 16.60 — Mv1 ‘Available shim thickness: F9.9A: 0.10, 0.14, 0.18 and 0.50 mm F9.9B: 0.10, 0.12, 0.15, 0.18, 0.30, 0.40 and 0.50 mm 3. Adjust: + Reverse gear shim thickness Adjustment steps: «Measure the dimension (Mv2). Shimming plate: ‘90890-06701 Digital caliper: 90890-06704 Va Ss Use the following equation to calculate the pi- niion shim thickness (T2). X SN St 10, 0.12, 0.15, 0.18, 0.30, 0.40 and 0.50 mm 618ILOWR| LOWER UNIT S BACKLASH MEASUREMENT NOTE: +Both forward and reverse gear backlash should be measured. +f both the forward and reverse gear backlash are large than specified, the pinion may be too high. + If both the forward and reverse gear backlash are smaller than specified, the pinion may be too low. + If either of these conditions exists, then check the pinion shim selection. 1, Measure: «Forward gear backlash Out of specification — Adjust. Backlash: T9.9/F9.9A: 0.26 ~ 0.77 mm F9.9/F9.9B: 0.23 ~ 0.70 mm Measurement steps: +Place the shift shaft in neutral. + Load the forward gear with the bearing housing puller on the propeller shaft. NOTE: Lightly tighten by hand until the pressure of the propeller shaft on the forward gear re- stricts movement enough to allow backlash measurement. Bearing housing puller: YB-6234/90890-06503 Universal puller: YB-6117 ‘Stopper guide stand: ‘90890-06501 down. “Attach the backlash indicator on the drive shatt. + Attach the dial gauge on the gear case, and make the dial gauge stem contact the mark on the indicator. 619LOWR| LOWER UNIT 620 Dial gauge: ‘YU-3097/90890-01252 Magnet base: YU-34481/90890-06705 Backlash indicator: ‘YB-6265/90890-06706 x *While pulling the drive shaft downward, slowly turn the drive shaft clockwise and ‘counterclockwise then measure the backlash when the drive shaft stops at each direction. +Determine the shims to be added or removed according to the specified. 79.9/F9.9A Less than To be decreased by 0.26 mm (0.51 - measurement) ‘More than| To be increased by 0.77 mm (measurement - 0.51) 25 F9.9/F9.9B Less than To be decreased by 0.23 mm (0.47 - measurement) 23 More than To be increased by 0.70 mm (measurement - 0.47) 23 Example: (T9.9/F9.9A) If measurement = 0.25 mm Decrease shim thickness by (0.51 — 0.25)/2.5 .26/2.5 = 0.10 mm If measurement = 1.26 mm Increase shim thickness by = (1.26 — 0.51)/2.5 0.75/2.5 = 0.3 mm Available shim thickness: a T9.9/F9.9A: 0.10, 0.14, 0.18, 0.35 and 0.50 mm F9.9/F9.9B: 0.10, 0.12, 0.15, 0.18, 0.30, 0.40 and 0.50 mmLOWR| LOWER UNIT & NOTE: Since the smallest shim available is 0.10 mm, if the measurement is between (T9.9/F9.9A) 0.26 and 0.77 mm or (F9.9/F9.9B) 0.23 and 0.70 mm do not change the shim. 2, Measure: + Reverse gear backlash Out of specification —- Adjust. $&] Backlash: 79.9/F9.9A: 0.51 ~ 1.02 mm. F9.9/F9.9B: 0.82 ~ 1.16 mm Measurement steps: *Place the shift shaft in neutral. + Load the reverse gear by installing the pro- eller without the front side spacer (P) and tighten the nut. NOTE: Lightly tighten by hand until the pressure of the propeller shaft on the reverse gear re- sticts movement enough to allow backlash measurement. + Set the lower unit upside down. + Attach the backlash indicator on the drive shatt. + Attach the dial gauge on the gear case, and make the dial gauge stem contact the mark ‘on the indicator. FZ Dial gauge: YU-3097/90890-01252 Magnet base: YU-34481/90890-06705 Backlash indicator: YB-6265/90890-06706 621[Lowe LOWER UNIT eS While pulling the drive shaft downward, slowly turn the drive shaft clockwise and counterclockwise then measure the backlash when the drive shaft stops at each direction. +Determine the shims to be added or removed according to the specified. 79.9/F9.9A Less than| To be decreased by 0.51 mm (0.77 - measurement) 25 ‘More than To be increased by 1.02 mm (measuremer 2) F9.9/F9.9B Less than| To be decreased by 0.82 mm (0.99 - measurement) 23 More than’ To be increased by 1.17 mm 19) Example: (T9.9/F9.9B) If measurement = 0.74 mm Decrease shim thickness by = (0.99 — 0.74)/2.3 = 0.25/23 = 0.11 mm If measurement = 1.79 mm Increase shim thickness by = (1.79 — 0.99)/2.3 = 0,80/2.3 = 0.35 mm Available shim thickness: T9.9/F9.9A: 0.10, 0.14, 0.18 and 0.50 mm. F9.9/F9.9B: 0.10, 0.12, 0.15, 0.18, 0.30, 0.40 and 0.50 mm Nove; Since the smallest shim available is 0.10 mm, it the measurement is between (T9.9/F9.9A) 0.51 and 1.02 mm or (F9.9/F9.9B) 0.82 and 1.17, mm do not change the shim. 622ILOWR| € | LOWER UNIT WATER PUMP 4. Install: + Dowel pin © + Gasket @ + Outer plate @ + Gasket @ + Woodrultf key © + Impeller © 2. Install: * Insert cartridge D * Bushing @ *Cover @ *Screw@® + Water pump housing ©) +Plate @ *Bolt ® NOTE: + Apply the impeller with water resistant grease. + Tur the drive shaft clockwise, when installing the water pump housing. LOWER UNIT 1. Install: + Dowel pin © + Lower unit @ +Bolt @ NOTE: + Set the shift cam to the reverse position. + Hold the shift rod nut in the lowest position. + Insert the drive shaft into the crankshaft, insert the water tube into the water seal, and insert the shift rod into the upper casing. 623LOWR € | LOWER UNIT 2. Install: «Shift rod © «Shift lever @ +Nut @ + Lock nut @ NOTE: Install the nut on the it in 5 turns. lever side and screw F9.9/F9.9B 624 3. Check: + Pressure Impossible to maintain the specified pressure for 10 seconds —> Reinstall. Checking steps: + Attach the Mity Vac to the oil level hole. | Mity Vac: ‘YB-35956/90890-06756 + Apply the specified pressure. Specified pressure: 100 kPa (1.0 kg/cm’, 14.2 psi) 4. Apply: + Gear oil Refer to page 3-14. PROPELLER 1. Install: (T89/F9.9A) + Spacer D Washer @ + Propeller @) +Nut @ +Cotter pn © Nut: Na] 13. Nm (1.3 m-kg, 9.4 ft-lb) 7. Insta: (F99/F9.9B) + Spacer +Propelier @ + Washer @) =Nut @ + Cotter pin © mM Nut: 13. Nm (1.3 m-kg, 9.4 ft-Ib)LOWR LOWER UNIT NOTE: — If the propeller nut does not align with the propeller shaft hole when the nut is tightened to specification, turn it in further so that they align. 6-25BRKT| CHAPTER 7 BRACKET UNIT UPPER CASING AND BOTTOM COWLING PREPARATION FOR REMOVAL INSPECTION Clamp lever Bottom cowling........ Oil pan and exhaust guide Exhaust manifold . Upper casing . Oil strainer. Shift mechanism. Sealing parts ....... Mount rubber. . ASSEMBLY AND INSTALLATION Upper casing Bottom cowling .. BRACKET UNIT..........-...0.2..- PREPARATION FOR REMOVAL REMOVAL POINTS Spring... .- INSPECTION .... ce Clamp and swivel bracket Tilt plate ASSEMBLY AND INSTALLATION STEERING HANDLE ....... bevel e tee eteeee PREPARATION FOR REMOVAL (T2.9MHIF9.9AM, T9.9EH/FS9AEM) PREPARATION FOR REMOVAL (F9.9MHIF9.9BM, F9.9EHIF9.9BEM) REMOVAL POINTS Ring nut .. INSPECTION Shift and throttle cables Steering handle ........... op eponeooo ASSEMBLY AND INSTALLATION ... Steering handle (T9.9/F9.94) Steering handle (F9.9/F9.98) . ma TA 7412 = TA = PAB, 713 713 = TAB 716 716 “TAT 718 2 7AB oe PAB. 2 TAB 2 TAB TAD 719 72BRKT T UPPER CASING AND BOTTOM COWLING S UPPER CASING AND BOTTOM COWLING PREPARATION FOR REMOVAL * Remove the power unit. * Remove the ground lead at the swivel bracket side. SNM (0.3 m-kg, 22 ft-lb) 51Nm (0.5 m-kg, 3.6 ft-Ib) 8Nm (0.8 m- -Ib) 10 Nm (1.0 m: 12Nm (1.2 m-kg, 8.7 ft-Ib) fo] =] moo a]>| 25 Nm (2.5 m-kg, 18 ft-1b)BRKT Extent of removal: UPPER CASING AND BOTTOM COWLING @ Bottom cowling removal _@ Upper casing removal ®© Mount rubber removal Extent of removal Order Part name Qty Remarks 1 | Cable end (Throttle) 2 | Cable end (Shitt) 79.9/F9.9A model only. 3 | Screw 4 | Shift lever F9,9/F 9.98 model only. 5__| Bolt 6 | Shiftrod pin 7 ‘| Bott 8 | Shift stay 9 | Panel stay 10_| Bott 11. | Bottom cowling 12 | Bolt 13 | Bolt 14 | Exhaust guide 15 _| Dowel pin 16 | Rubber seal 17 | Oilseal 18 | Pipe 19. | Relief valve 20 _| Seal 21 | Ollpan 22. | Dowel pin 23. | Upper casing 24 | Bolt 25 _| Rubber housing 26 | Mount rubber (Side) 27. | Mount rubber (Under) alruwanl(pornme[seaaalwsonalaaseoalssaaan 28 | Nut 29 | Bott 30__| Clamp Loosen the screw. 31__| Mount rubber (Upper) INSPECTION CLAMP LEVER 1. Inspect: *Clamp lever \ Wear/Damage — Replace. 72UPPER CASING AND BOTTOM COWLING 5 BOTTOM COWLING 1. Inspect: + Bottom cowling ‘Crack/Damage — Replace. OIL PAN AND EXHAUST GUIDE 1. Inspect: + Oil pan + Exhaust guide Crack/Damage -+ Replace. EXHAUST MANIFOLD 1. Inspect: + Exhaust manifold Carbon deposits — Clean. Crack/Corrosion —- Replace. UPPER CASING 1. Inspect: + Upper casing Crack/Damage —+ Replace. OIL STRAINER 1. Inspect: + Oil strainer Contamination -» Clean. Damage -» Replace. 7314 SHIFT MECHANISM 1. Inspect: BRKT! T UPPER CASING AND BOTTOM COWLING a + Bushing + Cable end Wear/Damage — Replace. SEALING PARTS 1. Inspect: + Rubber seal Crack/Damage —- Replace. MOUNT RUBBER 1. Inspect: * Mount rubber Wear/Damage —> Replace.|r | UPPER CASING AND BOTTOM COWLING ea ASSEMBLY AND INSTALLATION UPPER CASING 1. Install: + Mount rubber © + Rubber seal @ +Clamp @ +Plate @ + Bolt © NOTE: The clamp should be installed with the screwed side facing downward. Ng Screw: 3.Nm (0.3 mkg, 2.2 fb) * Stopper @ * Mount rubber @) *Bolt ® +Hose © +Seal@) . Install: + Upper casing © + Bracket @ +Nut @ Nut: 25 Nm (2.5 nkg, 18 ft1b) 75BRKT 1 UPPER CASING AND BOTTOM COWLING 2 4. Install: + Mount rubber (Under) © Mount rubber (Side) @ + Rubber housing @ + Ground lead @ +Bolt © 5. Install: +SealD +Gasket @ + Exhaust manifold @ + Oil pan @ Bolt © Ng Bolt: 12 Nm (1.2 mkg, 8.7 fib) NoTe; +Align the exhaust manifold with the oil pan hole. + Always use a new gasket. 6. Install: + Oil strainer © *Bolt @ + O-ring @ *Drain plug @ + Rubber damper ©) Ng Drain plug: 8 Nm (0.8 mkg, 5.8 tt1b) 7. Install: +Grommet © Water tube @ Nove: — + Align the hole in the oil pan with the projection in the grommet. + Install the water tube so that it position is not reversed.BRKT UPPEER CASING AND BOTTOM COWLING > 8. Install: + Exhaust guide D * O-ring @ + Relief valve ® + Grommet @ *Pipe guide @) + Screw © +Pipe @ + Rubber seal ® Ny Relief valve: 8 Nm (0.8 mkg, 5.8 ftb) CAUTION: Coat the screw with blue LOCTITE® (242). 9. Install * Oil seal © * Washer @) +Pipe @ * Bushing ® *Nut © + Seal © * Gasket @ Bolt ® Nut: 5. Nm (0.5 mekg, 3.6 ftelb) Bolt: 10 Nm (1.0 mekg, 7.3 ftelb) + Torque the bolts in the sequence embossed on the exhaust guide. ‘Install the pipes with their water discharge ‘end facing the oil pan. 10. instal: + Dowel pin © + Gasket @ + Bolt @ NOTE: Always use a new gasket. 7BRKT 1 UPPER CASING AND BOTTOM COWLING 11. Apply: + Gasket maker Onto both face of the gasket. NOTE: es Clean the contacting surface of crankcase. 12. Install: + Dowel pin ® + Gasket @ + O-ring @ + Rubber seal @ + Rubber seal 6) NOTE: Always use a new gasket. BOTTOM COWLING 1. Install: *Grommet D =Collar @ 2. Install: *Shitt stay O +Panel stay @ +Bolt @ + Front panel @ + Seal rubber ©) +Hinge pin © + Cotter pin @ + Grommet (shift rod) ® NOTE: Always use a new cotter pin. 5UPPER CASING AND BOTTOM COWLING 78 3. Install: +*Grommet © + Fu jel joint @ + Bolt © 1el hose @ *Clip + Engine stop switch © N Engine stop switch: 4.Nm (0.4 mkg, 2.9 ft'1b) 4, Inst fall: Bottom cowling © Washer @ + Bolt @ 2 . Inst tall: + Grommet (shift shaft) © +Grommet @) Water hose @ 2 Install: + Lever stay © + Washer @ Bushing @ +Clamp lever @ +Collar ©) Wave washer © Washer @ +Bolt ® + Rubber seal @ Bolt @BRKT| UPPER CASING AND BOTTOM COWLING 7. Install: + Shift link © + Bushing @ + Shift lever © + Shift arm @ + Accelerator stopper © + Shift arm © + Accelerator arm @ + Bushing © +Bolt © + Shift rod @ +Pin ® Washer @ *Cotter pin @ Cotter pin ® *Spring © + Bracket ® +Bolt D 8. Install: (T9.9MH/F9.9AM, F9.9MH/ F9.9BM) +Stay O Bolt @ + Guide @ + Start-in-gear protection wire @ © Install: (F9.9AE, F9.9AEM, F9.9BE, F9.9BEM) Stay D + Bolt @ + Neutral switch @BRACKET UNIT eS BRACKET UNIT PREPARATION FOR REMOVAL * Remove the power unit. * Remove the upper casing and bottom cowling. 12.Nm (1.2 m-kg, 8.7 ft-lb) 45 Nm (4.5 m-kg, 32 ft-Ib)BRKT BRACKET UNIT Extent of removal: @ Swivel bracket removal @ Swivel bracket disassembly @® Clamp bracket removal 24 | Tilt plate (Outer) 25 _| Drive lever is Pin [Extent of removal] Order Part name Qty Remarks 1 | Bolt 2 2 | Steering bracket 1 3 | Bolt 1 4 | Dowel pin 2 5 _| Steering shaft 1 6 | Washer 1 7 | Bushing 1 8 | Friction plate 1 9 | Swivel bracket 1 | 40_| Bushing - 1 11 | Oring 1 12. | Bushing }4 ® | 13 | Tilt pin 1 @ 14 | Nut 2 | 15_| Nut (Me) 1 16 | Clamp bracket 2 17 | Nut 2 18 | Pin 1 49 | Tit lever 1 || T9-9IF9.9A model only 20_| Pin 1 —_| 21 | Tilt plate (Inner) 1 22 | Spring 2. | Refer to "REMOVAL POINTS" 1 1 1 F9.9/F9.98 model only REMOVAL SPRING 1, Remove: Clip in @ Tilt plate (Inner) Q) Spring @ POINTS NOTE: Align the holes of the tit plate (Inner) and (Outer) ®, and removing the pin. 712BRKT BRACKET UNIT INSPECTION CLAMP AND SWIVEL BRACKET 1. Inspect: *Clamp bracket Swivel bracket CrackiDamage~Replace. TILT PLATE 1. Inspect: Tilt plate Crack/Demage-Replace. ASSEMBLY AND INSTALLATION 1. Install: (T9.9/F9.9A model) Tilt plate (Outer) @ Pin @ *Collor @) Spacer “Clip 6) |. Install: (F291F9.9B model) Tilt plate (Outer) @ Drive lever @) «Pin @ Color @ Clip © Install: “Spring ® «Tilt plate (Inner) @ Pin @ “Clip Nove: —_____ Align the holes of the tit plate (Inner) and (Outer), after installing the pin.BRACKET UNIT 3. Install (T9.9/F9.9A model) ‘*Rod (Long) @ ‘*Rod (Short) @) It lever @) B Install: *Rod (Short) @ “Spring @ sLever @) Install: *Clamp bolt ‘Bushing @ 2 Install: “Clamp bolt @) sLever @) “Bushing (Short) @) “Bushing (Long) @) Note: — Install the bushings with punch mark side ard. 7. Install: *Plate @ “Control plate @) *Screw @ oNut @ *Bolt ©) “Washer © sNnut @BRACKET UNIT > 8. Install: Lock plate @ ‘Washer Q) “Bolt @ “Washer plate @ sNut © NM Nut: 12Nm (1.2 mekg, 8.7 ftelb) 9. Install ‘*Washer (1) *Clamp bracket @) “Bolt @ *Collor @ ‘Washer 6) Nut © *Plate @ sNut ® ‘Nut (Clamp bolt): ‘45 Nm (45 m-kg, 325 ftslb) 10. Install: Bolt D lasher (wave) 2) Jasher plate @) sNnut @ 11. Install: *Steering shaft D ® “Steering bracket @) “Bolt @ ‘Washer ©) sBushing © Bolt: 13 Nm (1.3 mekg, 9.4 ftelb) 12. Install: “Friction piece @) “Bushing @ Oring @ Bushing @ *Ground lead @)BRKT| | STEERING HANDLE oon STEERING HANDLE PREPARATION FOR REMOVAL (T9.9MH/F9.9AM, T9.9EH/F9.9AEM) * Disconnect the control cables at engine side. * Disconnect the wire leads. ‘A [4 Nm (04 mkg, 29 fib) Extent of removal: @ Cable removal @ Steering handle disassembly Extent of removal [Order Part name ay Remarks 1 | Screw 2 2 4 : i 5 1_| Refer to "REMOVAL POINTS". 6 | Bolt 4 7 | Steering handle 1 1 8 |Screw~ 1 9 | Handle grip 1 i0_| Screw 2 11_ | Steering handle (Lefi) 2 42 | Bot? ( i 13. | Shift arm 1 14. | Cotter pin 1 15_| Shift cable 1 18 | Throttle cable 1 17 | Shift lever 1 48 | Nut 1 13_| Stop switch 1 7.16BRKT) iT STEERING HANDLE PREPARATION FOR REMOVAL (F9.9MH/F9.9BM, F9.9BEM) * Disconnect the control cables at engine side. Extent of removal: © Cable removal and Steering handle disassembly Extent of removal (Order Part name Qty Remarks T 9 ‘Screw Fitting plate Bolt Bracket Ring nut Refer to "REMOVAL POINTS". Bushing Steering handle 1 Screw Handle grip Screw Steering handle 2 Throttle cable tee | cates estes epee TATBRKT! T STEERING HANDLE > REMOVAL POINTS RING NUT 1. Remove: + Ring nut © Washer @ Washer (Wave) @ + Washer (Nylon) @ NOTE: + Tum the steering handle backward. + Fit a standard-head screwdriver into the slit in the ring nut. + Set the screwdriver using the steering bracket as a fulcrum, +Tum steering handle forward and loosen the ring nut. + Repeat this operation until the ring nut comes off. INSPECTION SHIFT AND THROTTLE CABLES 1. Inspect: + Shift cable = Throttle cable Bend/Damage —+ Replace. Unsmooth operation —- Replace. STEERING HANDLE 1. Inspect: + Steering handle Crack/Damage —> Replace. 78T STEERING HANDLE ASSEMBLY AND INSTALLATION ‘STEERING HANDLE (9.9/F9.9A) 1. Install: + Spring D *Bolt @ + Steering handle (right) @ + Stop switch © +Nut © hy 2. Install: Grommet © + Throttle cable @ NOTE: ——— Fit the inner cable end in the groove, and fit the outer cable end into the hole. Nut: 4.Nm (0.4 m-kg, 2.9 ft-Ib) 8. Install: + Shift arm @ * Shift cable @ *Collar @ + Washer @ + Cotter pin © Install: * Bushing ® + Shift lever @ + Wave washer @) + Shift arm @ + Washer @) +Bolt © +Nut @ NOTE: + Align the shift lever shaft end with the hole in ‘the shift arm. + Fit the shift arm collar to the Neutral position of the spring.STEERING HANDLE 5. Install: + Steering handle (left) D Screw @ Nove: + When installing steering handle, fit the throttle and shift cables correctly in place. + After installing steering handle, make sure the movement of shift lever by moving it. 6. Inst + Steering grip @ + Friction piece @ + Spring @ + Washer @ + Washer (Nylon) ©) + Screw © +Handle grip @ NOTE: Fit the handle grip correctly. 7. Install: + Steering handle D * Bolt (short) @ *Bolt (long) @ 8. Install: + Steering bracket D * Bushing @ + Washer (Nylon) @) Washer @ + Wave washer ©) Ring nut © + Tube @ NO’ ————— Pass the throttle and shift cables and stop switch leads through the steering handle on the steering bracket. 7-20BRKT STEERING HAND! LE 9. Tighten: +Ring nat © NOT ‘Screw in the ring nut by hand until tight, and fit aslotted-head screwdriver into the slit in the ring nut. Lock the screwdriver with the steering bracket, and tighten the ring nut by moving the steering handle back and forth. 10. Install: Nut D * Bracket @ Bolt @ * Shift cable @ + Throttle cable ® + Stopper bracket © + Fitting plate @ + Screw ® NOTE: When installing the shift cable, set the shift lever in the forward position. 11. Adjust: Throttle cable length Refer to page 3-24 ‘STEERING HANDLE (F9.9/F9.9B) 1. Install: + Throttle cable ® + Steering handle (upper) @ + Steering handle (under) @ Nut @ Screw ©) NOTE: Fit the inner cable end in the groove, and fit the ‘outer cable end into the hole. 2. Install: +*Steering grip @ + Friction piece @ + Spring @ + Washer @ + Washer (Nylon) ©) + Screw © Handle grip @ NOTE: Fit the handle grip correctly. 721BRKT T STEERING HANDLE 0 lO? 3. Install: + Steering bracket D *Bushing @ + Washer (Nylon) @ +Washer @ + Wave washer ©) «Ring nut © Tube @ NOTE: Pass the throttle cable through the steering handle on the steering bracket. NOTE: Screw in the ring nut by hand until tight, and fit aslotted-head screwdriver into the slit in the ring nut. Lock the screwdriver with the steering bracket, and tighten the ring nut by moving the steering handle back and forth. 5. Install: Nut D Bracket @ *Bolt @ * Throttle cable @ ‘* Stopper bracket @) * Fitting plate ® + Screw @ 6. Adjust: Throttle cable length Refer to page 3-24. 7-22ELEC EXPLODED DIAGRAM . WIRING DIAGRAM .... ELECTRICAL SYSTEM CHAPTER 8 ELECTRICAL SYSTEM T9.9MHIFO9AM FO.QMHIFO.9BM ....... : certs TO.9EHIFO.9AEM, FQ9EHIFO9BEM......... TO.9ERIFO.AE, F9,9ERIFO.9BE TOSMHIFOSAM .... F9.QMHIF99BM : TO9EHIFO9AEM 2.2.0... eee FO.QEHIFS.SBEM .. TO.9ER, FOSER . F9.9AE, F99BE : cee REMOTE CONTROL, SWITCH PANEL . INSPECTION Spark plug CDI system Pulser coil... Charge coil Lighting coil... Valve heater coil See Ignition coil : a7 Spark plug cap : CDI unit coon 818 Saree re Rectifier regulator ........ 06.006 es 2 BAD Figs = B20 Neutral switch . 820 Battery . 2+ 820 Engine stop switch 821 Stop switch . : 821 Starter switch ....... 821 Oil pressure switch 821 Oil pressure indicator lamp = B22 STARTER MOTOR ...2...0.00000ecc0s ea REMOVAL POINTS Pinion .... INSPECTION Pinion Brush .... Brush holder Armature ASSEMBLYELEC EXPLODED DIAGRAM EXPLODED DIAGRAM ‘9.9MH/F9.9AM ‘3Nm (0.3 m°kg, 22 ft-lb) 4 Nm (0.4 m-kg, 2.9 ft-lb) 7Nm (0.7 m-kg, 5.1 ft-lb) ojola]> 9Nm (0.9 m-kg, 6.5 ft-lb) 4 @—e @ Flywheel magneto @ Stator assembly @ Pulser coil @ Oi-pressure switch © Rectifier regulator 84 © CDI unit © Ignition coil ® Stop switch © Engine stop switch @® Oil-pressure indicator-lampELEC EXPLODED DIAGRAM F9.9MH/F9.9BM [_3Nm(OSm-kg,22ft-Ib) | 4Nm (0.4 m-kg, 29 ft-lb) 7Nm (0.7 m-kg, 5.1 ft-lb) ON ojala] @ Flywheet magneto @ Stator assembly @ Pulser coil @ Oil-pressure switch © Rectifier regulator © CDI unit @ Ignition coil © Engine stop switch © Oitpressure indicator-lamp 82ELEC EXPLODED DIAGRAM ‘T9.9EH/F9.9AEM, F9.9EH/F9.9BEM ‘A [_3Nm (0.3 m-kg, 22 ft-lb) B | 4Nm(04m-kg, 29 ft-lb) © | 7Nm (0.7 m-kg, 5.1 ft-Ib) D_[_9Nm (0.9 m-kg, 65 ft-Ib) Flywheel magneto Fuse Stator assembly CDI unit @ Pulser coil Ignition coil Starter motor ‘Stop switch (T9,9EH/F9.9AEM only) Oil-pressure switch Engine stop switch © Battery lead Starter relay @ Reatifier regulator Neutral switch Starter-switch Oil-pressure indicator-lamp 83ELEC EXPLODED DIAGRAM T9.9ER/F9.9AE, F9.9ER/F9.9BE A [_3Nm (0.3 m-kg, 22 ft-1b) B | 4Nm (04 m-kg, 29 ft-lb) | 7Nm (0.7 m-kg, 5.1 ft-Ib) D_[_9Nm (0.9 m-kg, 65 ft-lb Flywheel magneto Wiring-harness Stator assembly Rectifier regulator Pulser coil @ Fuse Starter motor CDI unit Oit-pressure switch Ignition coil Battery lead @ Starter relay ® Neutral switch (F9.9AE, F9.9BE only)ELEC WIRING DIAGRAM WIRING DIAGRAM ‘T9.9MH/F9.9AM 85 0 109 © ® oo wont ones ouseroaoera @ mtr (02 ona © pou (09 06 N20 wee @ ow u0019 ns dois e853 @ vous dois @ = Seose a owns annssaid-10 duoreopur ensseid:i @ 10 194 0NA 0 e840 ® woo 6uaubr) © 10 8 @ Aauesse 128 PoUyomUn Ih BsazeELEC WIRING DIAGRAM F9.9MH/F9.9BM nos oynoee @ ons dows ouse3 @) Kowns amnssord10 Q ue, sowwopu ainsso1610 @ Aquosse 18S 86ELEC WIRING DIAGRAM T9.9EH/F9.9AEM [3|6 owns ours @ pis dors eu6u3 @ uous dois @ yous onss0.d10 tue swopuy onsse.d10 @ 10 1004 ONEA 100 081840 v0 Gono @ 100 96rd @ Aequosse 1S o—eor—o—f oa} 87ELEC WIRING DIAGRAM F9.9EH/F9.9BEM eKUMrERIE | W/E 8 9 ° we: 9 eH /MOHOA : HVA, 4 eu emu /u001D | M 261019 wud om yorig oni Ba0F nog PeU/eMUM | Mt wun ao @ 00 wonu®| oven euouionser3 @ oyenos sownoee ojo ous (uy 02 A 21) Kowa @ jou 294s ‘ows eanen (02) 2504 @ ; ° $ ft clase sore zoELEC WIRING DIAGRAM T9.9ER, F9.9ER wore: OU /eMUM : U7 BSsa50 wn 120 © 00 woRet & ‘ena yousownonoers @ -ovenbes unceu @ fo 2UE18 @ (av o£ Azn howe © 2ojou 20S @ 02) 50s D ous einesaud40 @ 100-9804 one 09 840 ® 1 Boon © 160 Je8Id @ Aquosse ses © 89ELEC WIRING DIAGRAM F9.9AE, F9.9BE 810ELEC WIRING DIAGRAM © REMOTE CONTORL, SWITCH PANEL A Replace. ill Primary coil resistance: Orange (0) ~ Black (B) 0.08 ~ 0.11 Q at 20°C (68°F) NOTE: When measuring the resistance of 10 2 or less using the digital tester, the correct measurement cannot be obtained. Refer to “Lower resistance measurement’ 3, Measure: + Secondary coil resistance Out of specification — Replace. il ‘Secondary coil resistance: High tension cords 817 3.49 ~ 4.72 kQ at 20°C (68°F) ‘SPARK PLUG CAP 1. Inspect: + Spark plug cap Crack/Damage —- Replace. Replacement steps: + Remove the spark plug cap by turning the cap counter clockwise. NOTE: Avoid removing the plug cap by pulling the wire hard. Remove it by turning in and out. ‘Install the plug cap by turing the cap clockwise until it stops.ELEC ELECTRICAL SYSTEM TEES NOTE: + Di CDI UNIT 1. Measure: + CDI unit resistance Out of specification —> Replace. ital tester can not be used for this inspection. Use analogue tester. + CDI resistance values will vary from meter to meter, especially with electronic digital meters. For some testers, polarity of leads is reversed. B_ : Black W/R: White/Red Lo: Blue Br : Brown P: Pink O : Orange W : White Unit: ko ® B Br L wR P w ° e B 4x2 442 8x5 yotio | 4642 te =5 Br +500 + +500 +18 +150 | te 500+ $08 1000+ g, | 500+$03 | 18+ {8 | 150+} (T9.9/F9.9A) +70 70+28 (F9.9/F9.98) L spgt28 | +79+70 +45+45 | +79+7Z0 | «go +8 te 26713 | “7035 4595 | “70595 | “80°40 wR 74 +15, +15, +20 +16 “oo ast}! 15+}! 20+28 16+ 4 P +500 | 20:10 + 0 +500 +200 “co 500+ 508 1000+ 24, | 500+ $08 200+ $68 (19.9/F9.9A) 100+ 180 (F9.9/F 9.9) w 2 © @ @ 2 5 ° 4x2 +12 +12 15 +20 +13 sate 1atg 15st, 20759 sat} * : Needle swings once and returns to home position. 818ELEC ELECTRICAL SYSTEM TET STARTER RELAY 1. Inspect: + Brown lead terminal + Black lead terminal Loose —- Tighten. 2. Check: + Relay operation No function —- Replace. ‘Checking steps: + Connect a tester between the terminals of the starter relay. «Connect a 12 V battery. @ Brown lead —- Positive terminal @ Black lead —- Negative terminal + Check that there is continuity between the starter relay terminals. RECTIFIER REGULATOR (T9.9/F9.9A) 1. Measure: + Voltage drop Out of specification —- Replace. Measurement steps: + Select the function switch of digital tester to Diode inspection mode. + Measure the voltage drop. Tee] S775 S| on | awa | cin | wit | ee (Watck loso-o70] > [arene] > (D Greene [099-059 = Joao 080 = Dower [090=os0]07e~105] [oss 125 Dwrieroer] > (Ges [085 ~ons[oa0-os0|az0-oz0|a 819 *Measured value is not affected by tester leads connection.ELEC ELECTRICAL SYSTEM eS RECTIFIER REGULATOR (F9.9/F9.9B) 1. Check: Continuity Out of specification > Replace. NOTI Digital tester can not be used for this inspection. Tr] © |] ®@] 9] 0 \ & | Green | Greens | Aes | Black \ White e Testor [ Groen = Gi ° = (@Greeniwrte |= =] 9 = Ored * ee a @ Black © ° 2 Continuity. Discontinuity. FUSE 1. Check: + Fuse Blown —> Replace. il Fuse rating: 208 NEUTRAL SWITCH se 1. Check: a oO & Continuity Out of specification —- Replace. ire color wl Distance |_—Wire cotor__| Brown | Brown Free | 20205 mm @_| 079 +002 in) Push | 19205 mm @ | 075 +0029 oy? NOTE: 0-0" Indicates the terminals between which there is a continuity of electricity. BATTERY + Refer to page 3-10 ~ 3-12. 8-20ELEC ELECTRICAL SYSTEM @Q ENGINE STOP SWITCH I 1. Check: J +*Continuity O Out of specification + Replace. Wire color wil Lock plate white | Black ira.g/| ated F9.9A) Removed o—}+—0 insted F9.9/ a o_o (F9.9B Teta ad depen Setuton —— STOP SWITCH 14. Check: + Continuity Out of specification — Replace. il Wire color White Black Free Push o—}—0 STARTER SWITCH 1, Check: + Continuity Out of specification + Replace. wl Wire color Red Brown Free Push o—}—0 OIL PRESSURE SWITCH aS 1, Measure: “LO + Continuity Out of specification —- Replace. { Measurement steps: Connect a Mity Vac @. +Connect a tester @. FZ Mity Vac: YB-35956 / 90890-06756 2.21 + Apply the specified pressure.ELEC ELECTRICAL SYSTEM QS A Oil pressure switch: 0 =10 KPa - (0 =0.1 ko/em, 0 1.4 ps) _| Continuity 60 £10 kPa (0.6 +0.1 ka/em?, 8.5 1.4 psiy_| Discontinuity OIL PRESSURE INDICATOR LAMP 1. Check: + Oil pressure indicator lamp operation Out of specification —- Replace. Checking steps: + Connect the digital tester for engine side leads. @ Pink lead —- Positive terminal @ Black lead —- Negative terminal + Start the engine. + Check the voltage of output. al ‘Output voltage: More than AC 65 V 822 + Stop the engine. + Connect the oil pressure indicator lamp to engine side leads. + Start the engine. + Check the oil pressure indicator lamp for green indication. Be careful not to touch the ignition system leads while performing testing. High voltage electric shock may cause injury. CAUTION: Make the test with the motor placed in a test tank. NOTE: —— Before testing the oil pressure indicator lamp operation, oil pressure switch should be tested.ELEC STARTER MOTOR © STARTER MOTOR A [4 Nm (04 mks, 2.9 fib) e/ 7 ee, eT ~ “as § ~ Extent of removal: @ Starter motor disassembly @)Brush disassembly Extent of removal | Order Part name Oy Remarks 1 | Girclip 7 _| Always use a new circlip 2 | Pinion stopper 1_| Refer to “REMOVAL POINTS". 3 | Spring 1 4 | Pinion 1 5 _| Through bolt 2 6 | Rear cover 1 7 | Washer 1 |t=0.25 mm 8 | Stator 1 9 | Armature 1 10_| Washer 1 2.0 mm. 11 | Washer 1 0.15 mm 12 | Washer 1 13 | Front cover 1 14 | Screw 1 15_| Brush holder 1 16 | Brush spring 2 17_| Brush 2 REMOVAL POINTS PINION 1, Remove *Circlip D +Pinion stopper @) +Pinion © NOTE: Using a screw-driver, pry off the 8:23ELEC STARTER MOTOR 824 we INSPECTION PINION 1. Inspect: Pinion teeth Wear/Damage —> Replace. 2. Check: *Clutch movement Damage —- Replace. BRUSH 1, Measure: *Brush length @ Out of specification —» Replace brush hol Ider essembly. A Brush length: 9.0 ~ 12.5 mm (0.35 ~ 0.49 in) BRUSH 1. Che HOLDER ck: + Brush holder continuity Out of specification —- Replace. ail Brush holder continuity: Positive brush holder - Earth Discontinuity ARMATURE, 1. Insp + Cor ect: mmutator surface Dirt/Burnt —- Clean with #600 grit wei t-or-dry sandpaper. 2. Measure: * Commutator runout Use a dial-gauge and block. Out of soecification ~ Replace. x Runout 0.05 mm (0.002 in)ELEC STARTER MOTOR 3, Measure: +Commutator diameter Out of specification —> Replace. ‘Commutator diameter: 29.0 ~ 30.0 mm (1.14 ~ 1.18 in) 4, Measure: + Mica undercut depth Out of specification —- Cut it until specified depth is obtained. Mica undercut depth: 0.2 ~ 0.8 mm (0.008 ~ 0.03 in) NOTE: — Remove all particles of mica and metal by compressed ait 5. Check: + Armature coil continuity Out of specification + Replace. ‘Armature coil continuity: il Commutator segments Continuity Segment — Laminations _| Discontinuity] ‘Segment — Shaft Discontinuity 8.25STARTER MOTOR a ASSEMBLY 1. Install: +Brush © Brush spring @ + Brush holder @ + Rear cover @ + Screw © + Bushing © + Washer (Plain) @ + Washer (Spring) © +Nut @ Na Nut: 4.Nm (04 nkg, 2.9 ft1b) 2. Install: + Rear cover D +O-ting @ Washer (t = 0.25 mm) @ Armature @ Washer (t = 2.0 mm) © Washer (t = 0.15 mm) © + Washer (t = 1.0 mm) @ + Stator © + O-ring @ + Front cover @ + Through bolt @ CAUTION: Use care not to scratch the brushes when installing the armature on the rear cover. NOTE; Align the cut in the cover with the projection on the stator. 3. Install: Pinion © + Spring @ +Pinion stopper @ +Circlip @ NOTE: Make sure the circip tightly fits in the pinion stopper. 2.26TRBL sHTG_? CHAPTER 9 TROUBLESHOOTING ENGINE AND RELATED PARTS ... . ENGINE DOES NOT START/ENGINE TURNS OVER BUT STALLS/ ENGINE RUNS IRREGULARLY, STOPS OR IDLES ROUGHLY ... POWER LOSS ... ENGINE MISFIRES PRIME START . : ENGINE DOES NOT START WHEN ENGINE IS COLD ENGINE DOES NOT START WHEN ENGINE IS HOT/ ENGINE TURNS OVER BUT STALLS .... 99 ACCELERATION SYSTEM ssn 9-10 ENGINE STALL OR HESITATING IN FULL ACCELERATION .......... 9-10 ELECTRICAL SYSTEM . a O14 BATTERY IS NOT CHARGED ...... 9-11 GEAR SHIFTING .. O12 GEAR SHIFTING IS IMPOSSIBLE ... - 9-12 Manual handle model ... 912 9-43 Remote control mode!ITRBL] 4 ISHTG| {| ENGINE AND RELATED PARTS ENGINE AND RELATED PARTS ENGINE DOES NOT START/ENGINE TURNS OVER BUT STALLS/ ENGINE RUNS IRREGULARLY, STOPS OR IDLES ROUGHLY Check: Loosen the drain screw] YES [ Fuel Jand make sure fuel ar- |-—-]_Fuel is deteriorated or dirty. —-[Replace fuel ives at the carburetor. NO Fuel: Yes Empty or fuel level Top up the fuel tank is low. Tro. | pees YES | Reconnect/ LLeakage/Flattened/ pes Broken/Disconnected [No Priming pump: ves Check valve/Rubber Replace pump damaged [No Fuel joint: ME Damage/Leakage Poe RESTART, Yes NO Engine stop switch: YES Check te ork plate Sette ok plat in is out of place. place. NO Check: L Check that spark is| strong. Spark plug: Incorrect gap/Carbon | YES [ Agiust/Clean/ | deposits/Diry/Oily or Replace | burnt NO park plug cap: Faulty/No contact NO Yes Tgnition colt Incorrect resistance Replace NO u 5 5 a YES g Replaceghee ? ENGINE AND RELATED PARTS. YES Pulser coil: Incorrect resistance cee NO | YES Charge coi: | Incorrect resistance aa NO . Yes C.D. unit: | ves | _| Incorrect resistance naa NO No RESTART Check: [Check to see that the YES jcompression pressure is | “~~ __-| higher than specification PRIME START }800 kPa (8 kg/om?, 114 psi] NOTE: Set the throttle grip to FAST. NO Disassemble the engine and check the following parts: yes [Repiac Cylinder head gasket > Damage Adjust Piston Worn Cylinder wa | — Broken Piston ring ‘Scutfed Valve Contact with seat/ Valve tit — Wear incorrect Cam shaft Rocker shaft — Worn Rocker arm RESTART _}-——— 92‘TRBL| ISHTG| POWER LOSS Check: Boat is loaded Properly. ENGINE AND RELATED PARTS YES NO. Check: Check the distribution of the load on the boat: Improper load distribution, Overload. Yes Propeller load distribution, [No Boat hull: Fouled with seaweeds and shells. YES Clean boat hull [No Tilt angle: Improper YES Adjust [No) Transom height: Low or high/ Air draw/ Cavitation YES Adjust Irregularities of the lower unit. NO YES Propeller selection: Make sure the engine runs at 3,500 ~ 4,500 rpm with wide-open throttle. NO CRUISING No [res Reselection Propeller: Bent/Broken/Loosely/Fit Incorrect size Yes Replace NO YES Clean YES Replace 93 CRUISINGISHTG| ENGINE AND RELATED PARTS Check: |” 4 Irregularities of the carburetion. ] Yes YES ae Fuel Replace fuel/ Fuel is deteriorated or dirty lean fuel tank [NO Fuel hose: Yes Leakage/Bent/Kinked/ Ree Flattened/Broken e NO. Fuel fiter: Yes ea Clean NO Fuel pump: |_YES | Broken Ll? TNO. Carburetor: YES | Replace/ Clogged/Water is in mixture Glean [No ‘See PRIME START NO | CRUISING Check: ‘Check that spark is strong. T YES No ‘Spark plug: Incorrect gap/Carbon Med hee deposits/Dirty/Oily or burnt leplace NO ‘Spark plug cap: YES FaultyiNo contact Replace NO Ignition timing: YES | Replace Incorrect timing C.D. unit No NO_| cruisina a4TRBL sHTG, ? oomnle| Make sure the com-| pression pressure is| ENGINE AND RELATED PARTS YES [See higher than specifi- PRIME START cation. NO Disassemble the engine and check the following parts: Cylinder head gasket Piston Cylinder wai Piston ring Valve Intake } Exhaust ‘Cam shaft Rocker shaft Rocker arm —+ Damage Wor + Broken Scutfed Damage or ~ poor sealing — Worn YES | Replace/ Adjust CRUISING _J-—— 95TRBL SHTG ? ENGINE MISFIRES (First check for spark to find cause.) ENGINE AND RELATED PARTS Check: Irregularities of the carburation. NO yes _| Fuel: ves | pe, ~ L place fuel/ Fuels deteriorated or ee ity. [No Fuel filter: eS Clogged a NO 5 YES Carburetor: ea Clogged NO No oneck: | [ - RESTART ‘Check that spark {8 strong. T Yes No _| Spark plug: Yes Lno_| Sr Fan Caton £8 | nus ean deposits/Diry/Oily or burned NO ‘Spark plug cap: YES Broken or not tightly fitted aa NO | Ignition coi: Yes Defective, check resistance -- || Replace out of specification NO Ignition timing: |_YES | Replace Incorrect timing CDA. unit NO YES C.D Unit: ! Incorrect resistance ae NO NO f RESTART 96ITRBL| ISHTG ? check: _| | regularities of valve timing. No] | YES ENGINE AND RELATED PARTS Valve clearance: L Incorrect Adjust NO. Timing belt and timing gear: | YES Stretch/Wear Replace NO ‘Cam shaft: YES ‘Wear Replace NO. ‘Valve (intake, exhaust) Rocker arm wes) Rocker shaft: Wear Replace No. No RESTART Check: Make sure the compression pressure is higher than specification. No yes [See PRIME START Disassemble the engine and check the following parts: Cylinder head gasket —- Damage Piston Worn Cylinder wall } — Broken Piston ring Scutted Damage or — poor sealing Vato Intake Exhaust ‘Cam shaft Rocker shaft | Rocker arm — Worn YES Replace/ 97 Adjust RESTARTTRBL sHTG| ? PRIME START PRIME START ENGINE DOES NOT START WHEN ENGINE IS COLD Cheek: Irregularities of the | YES [ piston valve: YES _[Repiace the clectrothermal Stick carburetor assembly. valve. wi NO ° Beectrothermalvave ] YES [Repiace ine electro. helo: thermal valve. io change TNO No r — RESTART | oneck: || Tregudaries ofthe | YES [Carburiorsiow ce] YES [~ fuel passage. ce ‘ean No og NO Float height: Yes oa va NO Pilot screw: yes Out of specication nee NO No ' - RESTART Replace the carburetor.PRIME START ENGINE DOES NOT START WHEN ENGINE IS HOT/ ENGINE TURNS OVER BUT STALLS Check: irregulariies of the | ves [Valve heater com YES [Replace the stator electrothermal + resistance: assembly valve. Out of spe: NO [xo Electrothermal valve ] yes [Replace the electro- |_| resistance: thermal valve. ut of specication NO Piston valve: YES | Replace the Stick carburetor assembly NO No RESTART check: ireguarios ofthe |_YES [Carburetor slow or- | YES [5 fuel passage. cuit: ci NO ai NO Float height: YES LP pajust Incorrect NO Pilot screw: yes _| Out of specification aoe ‘I NO No a RESTART { Replace the carburetor. 99TRBL ISHTG ? ACCELERATION SYSTEM ACCELERATION SYSTEM ENGINE STALL OR HESITATING IN FULL ACCELERATION Check: Irregularities of the | YES [ Acceleration pump: | YES Replace the acceleration pump. Clog/Damage [| carburetor. 4 NO NO | No RESTART Replace the car- buretorTRBL] > ISHTG * ELECTRICAL SYSTEM ELECTRICAL SYSTEM BATTERY IS NOT CHARGED Check Irregularities of the electrical | YES _| Battery: NO} ada tias system. Fluid level correctly Replace YES Output voltage: NO __| Replace the 12 VI10 4,500 rimin stator assembly. YES Reetifier regulator: Yes Damage Replace No Lead wire: yes Faulty/Damage — Replace NO Lighting cok _yes ra Replace NO RECHECK RESTARTTRBL sHTG. ? GEAR SHIFTING GEAR SHIFTING GEAR SHIFTING IS IMPOSSIBLE WARNING Do not start engine during this inspection. MANUAL HANDLE MODEL and “Reverse”. ‘Move shift handle to "Neutral", "Forward" Turn propeller and check that gears are in “Neutral”, "Forward" and "Reverse". Check: Irregularities of the shifting system. YES Joint nut (Shift rod) Correctly Connect correctly. [yes Shift cable end (Shift arm side): Disconnected YES Connect TNO. Shift cable end (Shift lever side): Disconnected YES Connect [No Dogs (Clutch dog/Gears): Damage/Wear YES Replace NO. Shift cam: Damage/Wear Yes Replace a2 RESHIFTINGgees 2 GEAR SHIFTING REMOTE CONTROL MODEL are in "Neutral" and Gears are faulty. Turn the propeller and check that the gears Gears are not in “Neutral” and “Forward” Gears are in “Neutral” and "Forward" . Remote control is faulty. “Forward”. Check: Irregularities of the remote control box. No| | YES Cable end connector: Incorrectly connected or faulty. YES Adjust NO Remote control cable: Stuck (due to rust or salt) YES Replace NO. Linkage: Faulty YES Replace | No No Check: | f lregularties of the| shifting system, RESHIFTING YES Joint nut (Shift rod): Correctly NO. Connect correctly. YES Dogs (Clutch dog/Gears): Damage/Wear YES Replace NO. Shift cam: Damage/Wear Yes Replace 9413 RESHIFTING +>

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